DIRECT SOLAR ENERGY TO DEVICE TRANSMISSION
20230130351 · 2023-04-27
Inventors
Cpc classification
B64G1/428
PERFORMING OPERATIONS; TRANSPORTING
B64G1/10
PERFORMING OPERATIONS; TRANSPORTING
B64G1/44
PERFORMING OPERATIONS; TRANSPORTING
H02J50/27
ELECTRICITY
International classification
Abstract
System and method for direct solar energy to device transmission includes collecting and converting solar radiation energy to electrical energy by at least one satellite, generating a transmissive energy from the electrical energy, forming a transmissive energy beam, transmitting the energy beam from space directly to an electronic device located on Earth, receiving the energy beam by the electronic device's rectenna, converting the energy beam to alternating current, matching rectenna's antenna impedance with the rectenna's rectifying circuit impedance, rectifying the alternating current to direct current, and powering a load of the electronic device.
Claims
1. A method, comprising: collecting and converting solar radiation energy to electrical energy by at least one satellite; generating a transmissive energy from the electrical energy; forming a transmissive energy beam; and transmitting the energy beam from space directly to an electronic device located on Earth.
2. The method of claim 1, further comprising: receiving the energy beam by the electronic device's rectenna.
3. The method of claim 2, further comprising: converting the energy beam to alternating current.
4. The method of claim 2, further comprising: wherein the rectenna is integrated with the electronic device.
5. The method of claim 3, further comprising: matching the rectenna's antenna impedance with the rectenna's rectifying circuit impedance.
6. The method of claim 5, further comprising: rectifying the alternating current to direct current.
7. The method of claim 6, further comprising: powering a load of the electronic device.
8. A method, comprising: collecting and converting solar radiation energy to electrical energy by at least one satellite; generating a transmissive energy from the electrical energy; forming a transmissive energy beam; transmitting the energy beam from space directly to an electronic device located on Earth; receiving the energy beam by the electronic device's rectenna; converting the energy beam to alternating current; matching the rectenna's antenna impedance with the rectenna's rectifying circuit impedance; rectifying the alternating current to direct current; and powering a load of the electronic device.
9. A method of claim 8, further comprising: wherein the transmissive energy comprises microwave energy, radiofrequency energy, laser energy, or any combination thereof.
10. A method of claim 8, further comprising: wherein the at least one satellite comprises a solar radiation collection and converting means.
11. A method of claim 10, further comprising: wherein the solar radiation collection and conversion means comprises an optical rectenna configured to collect and convert electromagnetic radiation in the terahertz range, optical range, or both ranges.
12. A method of claim 11, further comprising: wherein the optical rectenna comprises a nantenna and a rectifier.
13. A method of claim 12, further comprising: wherein the nantenna is configured to receive solar radiation and convert it to alternating current.
14. A method of claim 12, further comprising: wherein the nantenna is manufactured by an additive manufacturing process.
15. A method of claim 12, further comprising: wherein the nantenna comprises a ground plane, an optical resonance cavity, and an antenna.
16. A method of claim 12, further comprising: wherein the nantenna comprises a carbon nanotube, graphene, a metal, or any combination thereof.
17. A method of claim 12, further comprising: wherein the rectifier comprises a matching circuit and a rectifying circuit.
18. A method of claim 17, further comprising: wherein the matching circuit is configured to match the nantenna's impedance with the optical rectenna rectifying circuit's impedance.
19. A method of claim 17, further comprising: wherein the rectifying circuit is configured to rectify the alternating current to direct current.
20. A method, comprising: collecting and converting solar radiation energy to electrical energy by at least one satellite; generating a transmissive energy from the electrical energy; forming a transmissive energy beam; transmitting the energy beam from space directly to an electronic device located on Earth; receiving the energy beam by the electronic device's rectenna; converting the energy beam to alternating current, wherein the rectenna is integrated with the electronic device; matching the rectenna's antenna impedance with the rectenna's rectifying circuit impedance; rectifying the alternating current to direct current; powering a load of the electronic device, wherein the transmissive energy comprises microwave energy, radiofrequency energy, laser energy, or any combination thereof, wherein the at least one satellite comprises a solar radiation collection and converting means, wherein the solar radiation collection and conversion means comprises a photovoltaic cell or an optical rectenna configured to collect and convert electromagnetic radiation in the terahertz range, optical range, or both ranges, wherein the optical rectenna comprises a nantenna and a rectifier, wherein the nantenna is configured to receive solar radiation and convert it to alternating current, wherein the nantenna is manufactured by an additive manufacturing process, wherein the nantenna comprises a carbon nanotube, graphene, a metal, or any combination thereof, wherein the rectifier comprises a matching circuit and a rectifying circuit, wherein the matching circuit is configured to match the nantenna's impedance with the optical rectenna rectifying circuit's impedance, and wherein the rectifying circuit is configured to rectify the alternating current to direct current.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] Example embodiments are illustrated by way of example and are not limited to the figures of the accompanying drawings, in which, like references indicate similar elements.
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DETAILED DESCRIPTION
[0022] Although the present has been described with reference to specific examples, it will be evident that various modifications and changes may be made without departing from the broader spirit and scope of the various examples. The modifications and variations include any relevant combination of the disclosed features. In addition, the components shown in the figures, their connections, couplings, relationships, and their functions, are meant to be exemplary only, and are not meant to limit the examples described herein.
[0023] System and method for space-based solar radiation energy collection and conversion for transmission from space directly to electronic devices without a terrestrial receiver or base station for distribution, which effectively eliminates or minimizes the usage of batteries and fossil fuels by substitution with an environmentally-friendly energy resource. This is made possible from the continual improvements in rectenna designs, which can be manufactured small and efficient enough to fit into electronic devices of all sizes. Due to the high altitudes of satellites, energy transmission may direct power more precisely and effectively to the devices. In addition, without the use of a ground receiver or base station for distribution, there may be minimal obstructions and interferences from terrestrial objects, such as, e.g., trees, mountain ranges, and buildings. Electronic devices may include portable devices, such as, e.g., smart phones, tablets, laptops, cameras; non-portable devices, such as, e.g., household appliances, desktop computers, automobiles, maritime vessels, and aircrafts; and implantable medical devices, such as, e.g., pacemakers, insulin pumps, and deep-brain stimulators.
[0024] Solar radiation is collected and converted into electrical energy, which is further converted into a transmissive energy, such as, e.g., microwave, radiofrequency (RF) wave and/or laser energy, by one or more satellites, and then transmitted directly to an electronic device located on Earth from space without an intermediary terrestrial distribution center, such as, e.g., a base station. Solar energy collection and conversion may include one or more optical rectennas, microwave or RF rectennas, photovoltaic or solar cells, and/or thermoelectric or thermionic devices located on the satellites. A rectenna is a receiving antenna that radiates at a predetermined frequency range comprising a rectifier that converts incoming electromagnetic energy into electricity, such as, e.g., direct current. For example, one or more optical antennas or nantennas of a rectenna, such as, e.g., an array, may harvest the solar energy, such as, e.g., in the terahertz (THz) or one of the optical regions of the electromagnetic spectrum, and then convert it to electrical energy by rectifiers of the rectenna. The wireless power transmission application may include a microwave or RF transmitter and/or a laser emitter that is configured to directionally beam towards a microwave or RF rectenna that is embedded within, or otherwise integrated with, the electronic device. For example, the rectenna may be integrated on the covering or “skin” of the device. An antenna of the microwave or RF rectenna collects the transmitted microwave, RF, and/or laser, and converts it into electrical energy by the microwave or RF rectenna's rectifier. This converted energy may be used to power the electronic device and/or to charge an energy reserve, such as, e.g., a battery.
[0025] Space-based solar power (SBSP) harvesting differs from ground-based systems and methods in that the means used to collect energy resides on one or more orbiting satellites instead of the earth's surface. Basing such in space results in a higher collection rate of solar energy due to the lack of a diffusing atmosphere. In a conventional ground-based system, a large percentage of the solar energy is lost on its way through the atmosphere by the effects of reflection and absorption. SBSP systems and methods may convert solar energy to a far-field emission, such as, e.g., a microwaves or radio wave and/or laser, outside of the atmosphere which effectively avoids these losses. In addition, there may be a longer collection period and the ability to collect solar energy continuously without the downtime that results from the earth's rotation away from the sun. Use of radiation energy from the sun is an effective and efficient manner that offers the possibility of providing electrical power without the problems of pollution control and waste disposal.
[0026]
[0027] A plurality of satellite 102 may be disposed in space, such as, e.g., in a geosynchronous orbit to Earth 114, such that at least one is illuminated by Sun 104 at all times. As an example, at an altitude of approximately 22,300 miles, a satellite 102 moving east to west would be stationary with respect to any point on Earth 114. At times the satellite 102 would pass through Earth 114's shadow. Thus having a plurality of satellite 102 in the same orbit but out of phase permits at least one to be illuminated while the other is in shadow. Such a phase difference may keep the plurality of satellite 102 above the horizon and in direct line of sight to the same point on Earth 114. Alternatively, or in addition, the plurality of satellite 102 may be configured in a low earth orbit to Earth 114. A network of satellite 102 may be employed to achieve the most effective system operation, and to supply transmissive energy 108 to widely dispersed points on Earth 114, either continuously or as required to meet peak power demands.
[0028] In addition, a second network of satellite 102 may be disposed between the first network of satellite 102 and the receiving electronic device 112 located on Earth 114, such that the first network collects solar energy and converts it to electrical energy before further converting the electrical energy to transmissive energy 108, then transmits energy 108 to the intermediary second network. The second network may collect energy 108 from the first network prior to distribution directly into user devices from space without a terrestrial distribution center or base station. The collected energy 108 from the second network may be converted to electrical energy, e.g., direct current, prior to reconverting back to energy 108 prior to distribution to user device 112. In addition, or alternatively, one or more satellite 102 of the second network comprises a reflector unit that reflects energy 108 from the first network directly to device 112 rather than collecting energy 108 from the first network, converting to electrical energy, reconverting back to energy 108, and then distributing energy 108 directly to device 112 from space. The reflector unit may comprise a reflecting dish instead of, e.g., microwave receiving and transmitting antennas and a microwave generator, and may have any suitable shape, such as, e.g., parabolic, and pattern, such as, e.g., mesh. When more than one network is employed, each network may contain a single satellite, or more.
[0029] In addition, or alternatively, the second network may comprise airborne vehicles, such as, e.g., drones, balloons, and/or aircrafts, that include the same mechanisms or systems for collecting and transmitting energy 108 as a satellite 102 of the second network would be configured to collect and transmit energy 108. In addition, or alternatively, the airborne vehicles may comprise reflector units for reflecting energy 108 from the first satellite network directly to user electronic devices from space or within the atmosphere. In some cases, one or both networks of satellite 102 may be disposed in a planetary orbit about Sun 104, instead of, or in addition to, Earth 114. The orbit may be circular, elliptical, or ascending/descending. If, on the other hand, it is not necessary to provide a continuous supply of electric power, then a single satellite 102 may be used, taking power at will or whenever it is positioned in solar energy receiving relationship with Sun 104. Thus by transmitting solar energy to Earth 114 in the form of transmissive energy 108, e.g., microwave, RF and/or laser energy, the effects of atmosphere, clouds and other physical influences may be essentially discounted. With a system and method that is designed to continuously receive solar energy, the amount of standby equipment and reliance on batteries may be eliminated or minimized. Finally, the use of solar energy does not deplete Earth 114's resources and presents no problems of pollution or waste removal.
[0030]
[0031] The service module may comprise a structural subsystem configured to provide a mechanical base structure and to shield internal circuitry from extreme temperature changes, the ambient environment, radiation effect and/or micrometeorite damage; a telemetry subsystem configured to monitor onboard equipment operations, transmits equipment operation data to an earth control station, and/or receive the control station's commands to perform equipment operation adjustments; a solar collector and converter 210, such as, e.g., an optical rectenna or nantenna, a microwave or RF rectenna, a photovoltaic or solar cell, and/or a thermoelectric or thermionic device, for harvesting solar radiation energy and converting it to electrical energy, and then further converting the electrical energy to a transmissive energy, such as, e.g., microwave, RF and/or laser energy, for beaming directly to electronic devices located on Earth; a thermal control subsystem configured to protect electronic equipment from extreme temperatures due to internally produced heat, external solar heat, and the freezing temperatures due to lack of sunlight exposure on different sides of central body 202; and an attitude and orbit control subsystem comprising attitude and orbit control sensors and actuators, e.g., propulsion mechanisms such as small rocket thrusters, configured to maintain the satellite in a predetermined orbital orientation and position, in addition to maintaining direction of the one or more antenna 206.
[0032] In
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[0035] Transmission lines may couple solar collector & converter 402 with energy generator 406, which is configured to convert the electric power developed in solar collector & converter 402 to a transmissive energy, e.g., microwave, RF and/or laser energy, so that it may be formed into a suitably shaped electromagnetic beam for transmission directly to electronic devices located on Earth from the satellite in space. Examples of energy generator 406 include, e.g., a laser, a klystron, a gyrotron, a traveling-wave tube, a twystron, backward-wave oscillators and amplifiers, and crossed-field devices which include resonant types, such as, e.g., a magnetron, and nonresonant backward and forward wave types, such as, e.g., an amplitron, carcinatron and dematron. A plurality of energy generator 406 may be employed to produce a predetermined amount of power, and may operate in phase synchronization with each other through phase control 408. This may be accomplished by the use of a controlled phase shifting network comprising phase shifters, such as, e.g., those incorporating ferrites, switched diodes, and variable-length line design techniques. Phase control 408 may operate in conjunction with a computing device, such as, e.g., a processor coupled to a memory for executing software programs. Beamformer 410 may comprise an electromagnetic radiation transmitter, such as, e.g., a phased array antenna. The phased array antenna may comprise a number of radiating elements in which the relative phases of the respective signals feeding the radiating elements are varied in such a way that the effective radiation pattern of the array is reinforced in a desired direction and suppressed in undesired directions. The radiation pattern of the beam may be formed into a desirable configuration with respect to the main beam shape and width, and to sidelobe energy distributions locked onto a receiving antenna of rectenna 414. These beam requirements may be met by generating the proper amplitude and phase source distributions over the transmitting antenna aperture, and by the use of additional mechanical or electronic beam steering and alignment mechanisms where necessary. Guidance & control 418 of beamformer 410 may be adapted to achieve alignment of antennas to aim the total array—or in effect the center of the transmitted microwave energy beam—toward the center of the receiving antenna of rectenna 414, and to effect the necessary phasing of energy generator 406. In the alignment of the panels of the array, it may first be necessary to establish a reference plane, which may be defined by the axis of a rotating laser. Antenna guidance may be accomplished by, e.g., gas-fired rockets and/or ion engines.
[0036]
[0037]
[0038] An optical rectenna may be fixated to a solar energy harvesting satellite, and may comprise nantenna 512 coupled with rectifier 516. Any type of rectenna may be used, such as, e.g., dual frequency band, multiband, broadband, narrowband, wideband, multisource, and coplanar waveguide. Rectifier 516 may be configured in the unit ranges of millimeters, micrometers, or nanometers, such as, e.g., 0.01 nm to 50 mm. Solar radiation 514 may be in the form of an electromagnetic radiation, such as, e.g., ultraviolet, visible and/or infrared radiations, emitted from the sun. Receiving nantenna 512 collects solar radiation 514 from the sun and converts the electromagnetic energy to electrical energy, e.g., alternating current, by resonating at predetermined frequency bands. The electrical energy is then passed to rectifier 516, which comprises matching circuit 508 and rectifying circuit 510, coupled to a microwave, RF and/or laser energy generator. In some cases, nantenna 512 may be connected to a filter comprising one or more capacitors connected to one or more inductors. The filter acts as a harmonic rejection device cancelling unwanted waves and stopping the signals' re-radiation back into free space. In general, rectifier 516 may be a nonlinear circuit formed by a rectification diode-capacitor combination. Nantenna 512 delivers alternating current to impedance matching circuit 508, which may be configured to match the impedance of receiving nantenna 512 to rectifying circuit 510, such as, e.g., nantenna 512's impedance is 50 Ohms and rectifying circuit 508's impedance is 50 Ohms. Matching circuit 508 may comprise one or more capacitors connected with one or more inductors. Exact matching provides maximum output voltage for the rectenna with minimum transmission losses.
[0039] Rectifying circuit 510 comprises one or more diodes, such as, e.g., a metal-insulator-metal (MIM) tunneling diode, configured to receive alternating current from matching circuit 508 and converts it to direct current power. In some cases, the electrical energy is not converted to direct current from the alternating current. Rectifying circuit 510 can be of any type, such as, e.g., a single-diode configuration in series or shunt format, dual-diode structure, voltage multiplier or a hybrid circuit. Once the rectification is complete, the signal may be passed through a filter to remove the fundamental frequency signal and harmonics generated by the nonlinear characteristic of the diode and smooth the output signals from any distortions. The captured electrical energy is then supplied to the microwave, RF and/or laser energy generator to produce microwave, RF and/or laser energy to be transmitted directly to user electronic devices located on Earth. In some cases, a network of a plurality of rectifier 516 may be used with one or more nantenna 512.
[0040] In some cases, a network of a plurality of optical rectennas may be employed with each satellite. For example, means for spectral splitting may passively or actively split electromagnetic radiation into different spectral bands, each of which is absorbed by one or rectennas having an operating voltage that optimizes the power conversion efficiency for that band. Spectral splitting can be accomplished by numerous means, such as, e.g., employing a variety of nantennas that are sensitive to a different electromagnetic frequency bands, or through a spectral splitting apparatus such as a prism.
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[0044] In some cases, the nantenna may comprise graphene, which may be a one-atom-thick, two-dimensional carbon crystal. Graphene's unique structure may permit electrons that are able to move with minimal resistance. In some cases, the nantenna may comprise a dielectric resonator (DR), which is a nonmetallized material, such as, e.g., ceramic. In some cases, the nantenna may comprise polydimethylsiloxane (PDMS), such as, e.g., in a form of a lens. In some cases, a thermopile nantenna may be utilized to capture infrared light having heat signatures to convert thermal waves into output voltage. A thermopile nantenna may be formed by a plurality of thermocouples connected either in series or parallel configuration. In some cases, the nantenna may comprise arrays of single- or multi-wall carbon nanotubes (CNT) that are coupled to a nanoscale rectifying diode.
[0045]
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[0047] Rectifying circuit 910 comprises one or more diodes, such as, e.g., a Schottky diode configured to receive alternating current from matching circuit 908 and converts it to direct current power. In some cases, the electrical energy is not converted to direct current from the alternating current. Rectifying circuit 910 can be of any type, such as, e.g., a single-diode configuration in series or shunt format, dual-diode structure, voltage multiplier or a hybrid circuit. Once the rectification is complete, the signal may be passed through a filter to remove the fundamental frequency signal and harmonics generated by the nonlinear characteristic of the diode and smooth the output signals from any distortions. The captured electrical energy is then supplied to load 912, the electronic device's component or portion of a circuit that consumes electric power, or to a reserve, such as, e.g., a battery, for operating the device. In some cases, a network of a plurality of rectifier 906 may be used with one or more antenna 904.
[0048] In some cases, a network of a plurality of microwave or RF rectennas may be employed with each electronic device. For example, means for spectral splitting may passively or actively split electromagnetic radiation into different spectral bands, each of which is absorbed by one or rectennas having an operating voltage that optimizes the power conversion efficiency for that band. Spectral splitting can be accomplished by numerous means, such as, e.g., employing a variety of antennas that are sensitive to a different electromagnetic frequency bands, or through a spectral splitting apparatus such as a prism.
[0049]
[0050] The system memory 1032 may include volatile memory 1033 and nonvolatile memory 1034. Nonvolatile memory 1034 may include read only memory (ROM), programmable ROM (PROM), electrically programmable ROM (EPROM), electrically erasable ROM (EEPROM), or flash memory. Volatile memory 1033, may include random access memory (RAM), synchronous RAM (SRAM), dynamic RAM (DRAM), synchronous DRAM (SDRAM), double data rate SDRAM (DDR SDRAM), enhanced SDRAM (ESDRAM), Synchlink DRAM (SLDRAM), or direct Rambus RAM (DRRAM).
[0051] The device also includes storage media 1036, such as removable/non-removable, volatile/nonvolatile disk storage, magnetic disk drive, floppy disk drive, tape drive, Jaz drive, Zip drive, LS-100 drive, flash memory card, memory stick, optical disk drive such as a compact disk ROM device (CD-ROM), CD recordable drive (CD-R Drive), CD rewritable drive (CD-RW Drive) or a digital versatile disk ROM drive (DVD-ROM). A removable or non-removable interface 1035 may be used to facilitate connection.
[0052] The device may further include software to operate, such as an operating system 1011, system applications 1012, program modules 1013 and program data 1014, which are stored either in system memory 1032 or on disk storage 1036. Various operating systems or combinations of operating systems may be used.
[0053] Input device 1022 may be used to enter commands or data, and may include a pointing device such as a mouse, trackball, stylus, touch pad, keyboard, microphone, joystick, game pad, satellite dish, scanner, TV tuner card, sound card, digital camera, digital video camera, web camera, and the like, connected through interface ports 1038. Interface ports 1038 may include a serial port, a parallel port, a game port, a universal serial bus (USB), and a 1394 bus. The interface ports 1038 may also accommodate output devices 1021. For example, a USB port may be used to provide input to the mobile device and to output information from the mobile device to an output device 1021. Output adapter 1039, such as video or sound cards, is provided to connect to some output devices such as monitors, speakers, and printers.
[0054] The position detection device 424 may be a device that communicates with a plurality of positioning satellites, e.g., GPS satellites, to determine the geographical location of the mobile device, and thus the user. To determine the location of the user, the position detection device 1024 searches for and collects GPS information or signals from four or more GPS satellites that are in view of the position detection device 1024. Using the determined time interval between the broadcast time and reception time of each signal, the position detection device 1024 may calculate the distance of the user relative to each of the four or more GPS satellites. These distance measurements, along with the position and time information received in the signals, allow the position detection device 1024 to calculate the geographical location of the user.
[0055] Example configurations of receiving antennas from a microwave or RF rectenna embedded within an electrical device can be found in
[0056]
[0057] Operation 1106 forms a transmissive energy beam by an electromagnetic radiation transmitter, such as, e.g., a phased array antenna. The phased array antenna may comprise a number of radiating elements in which the relative phases of the respective signals feeding the radiating elements are varied in such a way that the effective radiation pattern of the array is reinforced in a desired direction and suppressed in undesired directions. The radiation pattern of the beam may be formed into a desirable configuration with respect to the main beam shape and width, and to sidelobe energy distributions locked onto a receiving antenna of a rectenna. These beam requirements may be met by generating the proper amplitude and phase source distributions over the transmitting antenna aperture, and by the use of additional mechanical or electronic beam steering and alignment mechanisms where necessary. Alignment of antennas may be achieved to aim the total array—or in effect the center of the transmitted microwave energy beam—toward the center of the receiving antenna of the rectenna, and to effect the necessary phasing of the energy generator. In the alignment of the panels of the array, it may first be necessary to establish a reference plane, which may be defined by the axis of a rotating laser. Antenna guidance may be accomplished by, e.g., gas-fired rockets and/or ion engines. Operation 1108 transmits the energy beam directly to the electronic device from the satellites located in space.
[0058]
[0059] The concept behind optical rectennas is essentially the same as for traditional microwave or RF rectennas. Incident light on the antenna causes electrons in the antenna to move back and forth at the same frequency as the incoming light. This is caused by the oscillating electric field of the incoming electromagnetic wave. The movement of electrons is an alternating current in the antenna circuit. To convert this to direct current, the alternating current must be rectified, which is typically accomplished with a diode. The resulting direct current can then be used to power an external load.
[0060] Antennas tend to be a similar size to the wavelength at which they operate, so a very tiny optical antenna or nantenna requires a challenging nanotechnology fabrication process. Because of limitations in nanotechnology fabrication, it has previously not been possible to develop, at a large-scale, rectennas that can operate in the THz or or optical ranges of the electromagnetic spectrum, such as, e.g., ultraviolet, visible and/or infrared radiations. Current nantennas are produced using electron beam lithography, which may be slow and relatively expensive because parallel processing is not possible.
[0061] An improved system and a method to manufacture optical antennas or nantennas at a nano-scale using additive manufacturing, e.g., 3D Printing, where ink or aerosol jets deposit material such as, e.g., aluminum, gold, silver, carbon, a dielectric material, doped silicon, gallium arsenide, silicon germanide, gallium nitride, molybdenum and copper, is disclosed. The aforementioned materials can be sintered at high temperatures, and therefore are amenable to integrated manufacture. Compared with traditional methods, this process may be inherently precise and repeatable, has much higher geometric and spatial resolutions, and produces higher density components with less material waste. In addition, a key advantage for purposes of this invention is that more complex shapes that were not possible before can now be printed, which can be used to improve specification and/or structural integrity of the product.
[0062]
[0063] A typical implementation of an additive manufacturing process begins with defining a three-dimensional geometry of the product using computer-aided design (CAD) software. This CAD data is then processed with software that slices the model into a plurality of thin layers, which are essentially two-dimensional. A physical part is then created by the successive printing of these layers to recreate the desired geometry. This process is repeated until all the layers have been printed. Typically, the resulting part is a “green” part, which may be an unfinished product that can undergo further processing, e.g., sintering. The green part may be dense and substantially non-porous.
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[0065]
[0066] A number of examples have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the claimed invention. In addition, the logic flows depicted in the figures do not require the particular order shown, or sequential order, to achieve desirable results. Other steps may be provided, or steps may be eliminated, from the described flows, and other components may be added to, or removed from, the described systems. Accordingly, other examples are within the scope of the following claims.
[0067] It may be appreciated that the various systems, methods, and apparatus disclosed herein may be configured in a machine-readable medium and/or a machine accessible medium, and/or may be performed in any order. The structures and modules in the figures may be shown as distinct and communicating with only a few specific structures and not others. The structures may be merged with each other, may perform overlapping functions, and may communicate with other structures not shown to be connected in the figures. Accordingly, the specification and/or drawings may be regarded in an illustrative rather than a restrictive sense.