Integral thermoelectric generator for wireless devices

Abstract

Electrical power is produced by a first process component, a first heat pipe formed in part by a first cavity within the first process component, and a thermoelectric generator assembly. The thermoelectric generator assembly is thermally coupled on one side to a heat sink and on the other side to the first heat pipe. The first process component is in direct contact with a first process fluid and the first cavity is proximate the first process fluid. The thermoelectric generator assembly produces electrical power.

1 . An apparatus comprising:
 a first process component for directly contacting a first process fluid, the first process component having a first cavity proximate the first process fluid;   a first heat pipe formed in part by the first cavity, the first heat pipe comprising a first working fluid; and   a thermoelectric generator assembly; wherein the first heat pipe is thermally coupled to a first side of the thermoelectric generator assembly and a heat sink is thermally coupled to a second side of the thermoelectric generator assembly; wherein the thermoelectric generator assembly produces electrical power:   
     
     
         2 . The apparatus of  claim 1 , further comprising a wireless transceiver, wherein the electrical power produced by the thermoelectric generator assembly at least partially powers the wireless transceiver. 
     
     
         3 . The apparatus of  claim 2 , further comprising a data router, wherein the electrical power produced by the thermoelectric generator assembly at least partially powers the data router. 
     
     
         4 . The apparatus of  claim 1 , further comprising a transducer, wherein the electrical power produced by the thermoelectric generator assembly at least partially powers the transducer. 
     
     
         5 . The apparatus of  claim 1 , further comprising an energy storage device for storing the electrical power. 
     
     
         6 . The apparatus of  claim 1 , wherein the first process component is one of a pipe flange, an orifice plate flange, an orifice plate, a thermowell, an averaging pitot tube, a stream trap, a flow tube, a flow straightening element, a control valve, a shut-off valve, a pressure relief valve, a pressure manifold, a valve manifold, a pump housing, a filter housing, a pressure sensor remote seal, a level switch, a contacting radar level gauge, a vortex flow meter, a coriolis meter, a magnetic flow meter, a turbine meter, and a flow restrictor. 
     
     
         7 . The apparatus of  claim 1 , wherein the heat sink is at least one of ambient air, water, a second process fluid, earth, a building, and an earthen berm. 
     
     
         8 . The apparatus of  claim 1 , wherein the first working fluid comprises at least one of water, ammonia, methanol, and ethanol. 
     
     
         9 . The apparatus of  claim 1 , wherein the first heat pipe is further formed in part by a flexible tube. 
     
     
         10 . The apparatus of  claim 1 , wherein the first heat pipe further comprises a wicking device. 
     
     
         11 . The apparatus of  claim 10 , wherein the wicking device is comprised of at least one of a sintered ceramic, metal mesh, metal felt, and metal foam. 
     
     
         12 . The apparatus of  claim 10 , wherein the wicking device is comprised of grooves on the interior surface of the heat pipe. 
     
     
         13 . The apparatus of  claim 1 , further comprising:
 a heat transfer device; and   the thermoelectric generator assembly comprises:
 a first heat spreader; and 
 a thermoelectric element, 
 wherein the first heat spreader is attached to a first side of the thermoelectric element to thermally couple the first side of the thermoelectric generator assembly to the first heat pipe; and 
   wherein the heat transfer device thermally couples the heat sink to the second side of the thermoelectric generator assembly.   
     
     
         14 . The apparatus of  claim 13 , further comprising thermal insulation between at least a portion of the first process component and the heat transfer device. 
     
     
         15 . The apparatus of  claim 13 , wherein the heat transfer device comprises at least one of a pin-fin heat exchanger and a finned heat exchanger. 
     
     
         16 . The apparatus of  claim 13 , wherein:
 the thermoelectric generator assembly further comprises a second heat spreader;   the heat transfer device comprises a second heat pipe; and   the second heat spreader is attached to a second side of the thermoelectric element to thermally couple the second side of the thermoelectric generator assembly to the second heat pipe.   
     
     
         17 . The apparatus of  claim 16 , wherein the heat sink is a second process fluid and the heat transfer device further comprises:
 a second process component for directly contacting the second process fluid, the second process component having a second cavity proximate the second process fluid;   wherein the second heat pipe is formed in part by the second cavity, the second heat pipe comprising a second working fluid.   
     
     
         18 . The apparatus of  claim 17 , wherein at least one of the first working fluid and the second working fluid comprises at least one of water, ammonia, methanol, and ethanol. 
     
     
         19 . The apparatus of  claim 17 , wherein at least one of the first heat pipe and the second heat pipe is further formed in part by a flexible tube. 
     
     
         20 . The apparatus of  claim 17 , wherein at least one of the first heat pipe and the second heat pipe further comprises a wicking device. 
     
     
         21 . The apparatus of  claim 20 , wherein the wicking device is comprised of at least one of a sintered ceramic, metal mesh, metal felt, and metal foam. 
     
     
         22 . The apparatus of  claim 20 , wherein the wicking device is comprised of grooves on the interior surface of the heat pipe. 
     
     
         23 . A system comprising:
 a wireless field device network;   a wireless device in wireless communication with the wireless field device network; and   a first process component for directly contacting a first process fluid, the first process component having a first cavity proximate the first process fluid;   a first heat pipe formed in part by the first cavity, the first heat pipe comprising a first working fluid; and   a thermoelectric generator assembly, wherein the first heat pipe is thermally coupled to a first side of the thermoelectric generator assembly and a heat sink is thermally coupled to a second side of the thermoelectric generator assembly;   wherein the thermoelectric generator assembly provides electrical power to the wireless device.   
     
     
         24 . The system of  claim 23 , wherein the wireless device is one of a wireless transceiver, a wireless data router, and a wireless field device. 
     
     
         25 . The system of  claim 23 , wherein the wireless field device network comprises a gateway, and wherein the thermoelectric generator assembly provides electrical power to the gateway. 
     
     
         26 . The system of  claim 23 , wherein the wireless field device network comprises at least one of a remote telemetry unit and a backhaul radio and wherein the thermoelectric generator assembly provides electrical power to at least one of the remote telemetry unit and the backhaul radio. 
     
     
         27 . The system of  claim 23 , wherein the process component is one of a pipe flange, an orifice plate flange, an orifice plate, a thermowell, an averaging pitot tube, a stream trap, a flow tube, a flow straightening element, a control valve, a shut-off valve, a pressure relief valve, a pressure manifold, a valve manifold, a pump housing, a filter housing, a pressure sensor remote seal, a level switch, a contacting radar level gauge, a vortex flow meter, a coriolis meter, a magnetic flow meter, a turbine meter, and a flow restrictor. 
     
     
         28 . The system of  claim 23 , wherein the heat sink is at least one of ambient air, water, a second process fluid, earth, a building, and an earthen berm. 
     
     
         29 . The system of  claim 23 , wherein the first working fluid is at least one of water, ammonia, methanol, and ethanol. 
     
     
         30 . The system of  claim 23 , wherein the first heat pipe further comprises a wicking device. 
     
     
         31 . The system of  claim 30 , wherein the wicking device is comprised of at least one of a sintered ceramic, metal mesh, metal felt, and metal foam. 
     
     
         32 . The system of  claim 30 , wherein the wicking device is comprised of grooves on the interior surface of the heat pipe. 
     
     
         33 . The system of  claim 23 , further comprising:
 a heat transfer device; and   the thermoelectric generator assembly comprises:
 a first heat spreader, and 
 a thermoelectric element, 
 wherein the first heat spreader is attached to a first side of the thermoelectric element to thermally couple the first side of the thermoelectric generator assembly to the first heat pipe; and 
   wherein the heat transfer device thermally couples the heat sink to the second side of the thermoelectric generator assembly.   
     
     
         34 . The apparatus of  claim 33 , further comprising thermal insulation between at least a portion of the first process component and the heat sink. 
     
     
         35 . The system of  claim 33 , wherein the heat transfer device comprises at least one of a pin-fin heat exchanger and a finned heat exchanger. 
     
     
         36 . The system of  claim 33 , wherein:
 the thermoelectric generator assembly further comprises a second heat spreader;   the heat transfer device comprises a second heat pipe; and   the second heat spreader is attached to a second side of the thermoelectric element to thermally couple the second side of the thermoelectric generator assembly to the second heat pipe.   
     
     
         37 . The system of  claim 36 , wherein the heat sink is a second process fluid and the heat transfer device further comprises:
 a second process component for directly contacting the second process fluid, the second process component having a second cavity proximate the second process fluid;   wherein the second heat pipe is formed in part by the second cavity, the second heat pipe comprising a second working fluid.   
     
     
         38 . The system of  claim 37 , wherein at least one of the first working fluid and the second working fluid comprises at least one of water, ammonia, methanol and ethanol. 
     
     
         39 . The system of  claim 37 , wherein the at least one of the first heat pipe and the second heat pipe is further formed in part by a flexible tube. 
     
     
         40 . The system of  claim 37 , wherein the at least one of the first heat pipe and the second heat pipe further comprises a wicking device. 
     
     
         41 . The system of  claim 40 , wherein the wicking device is comprised of at least one of a sintered ceramic, metal mesh, metal felt, and metal foam. 
     
     
         42 . The system of  claim 40 , wherein the wicking device is comprised of grooves on the interior surface of the heat pipe. 
     
     
         43 . A method for generating electrical power for use in a wireless field device network, the method comprising:
 contacting a process component with a process fluid;   conducting heat between the process fluid and a surface of a sealed cavity within the process component;   transferring heat between the surface of the sealed cavity and a thermoelectric generator assembly by vaporizing and condensing a working fluid;   conducting heat through the thermoelectric generator assembly;   transferring heat between the thermoelectric generator assembly and a heat sink by at least one of convection and conduction; and   generating electrical power from the conduction of heat through the thermoelectric generator assembly.   
     
     
         44 . The method of  claim 43 , wherein the transferring heat between the surface of the sealed cavity and a thermoelectric generator assembly further comprises wicking the condensed working fluid toward the vaporizing working fluid. 
     
     
         45 . The method of  claim 43 , further comprising insulating the thermoelectric generator assembly from heat transfer with the process fluid other than by condensing and vaporizing the working fluid. 
     
     
         46 . The method of  claim 43 , further comprising powering at least partially a wireless device with the generated electrical power.