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Stanford Telecommunications, Inc.

Richard C Thuss

Scott K Mccall

Harry B Radousky

James Howard Leveque, Iii

Joseph McAlpin Bozzay

Alexander Baker

Thomas A Russell

Nathan Woollett

A product includes an array of cold spray-formed structures. Each of the structures is characterized by having a defined feature size in at least one dimension of less than 100 microns as measured in a plane of deposition of the structure, at least 90% of a theoretical density of a raw material from which the structure is formed, and essentially the same functional properties as the raw material. A product includes a cold spray-formed structure characterized by having a defined feature size in at least one dimension of less than 100 microns as measured in a plane of deposition of the structure, at least 90% of a theoretical density of a raw material from which the structure is formed, and essentially the same functional properties as the raw material.

Products and applications for the templated fabrication of materials using cold spray deposition

An apparatus and method perform supersonic cold-spraying to deposit N and P-type thermoelectric semiconductor, and other polycrystalline materials on other materials of varying complex shapes. The process developed has been demonstrated for bismuth and antimony telluride formulations as well as Tetrahedrite type copper sulfosalt materials. Both thick and thin layer thermoelectric semiconductor material is deposited over small or large areas to flat and highly complex shaped surfaces and will therefore help create a far greater application set for thermoelectric generator (TEG) systems. This process when combined with other manufacturing processes allows the total additive manufacturing of complete thermoelectric generator based waste heat recovery systems. The processes also directly apply to both thermoelectric cooler (TEC) systems, thermopile devices, and other polycrystalline functional material applications.

Apparatus, and process for cold spray deposition of thermoelectric semiconductor and other polycrystalline materials and method for making polycrystalline materials for cold spray deposition

An apparatus and methods to make a product using supersonic cold-spray deposition of brittle functional materials in fine and micro features down to 10 &#x3bc;m in minimum dimension. The process may use semiconductors such as bismuth and antimony telluride formulations, and hard magnetic materials such as neodymium iron boride and strontium ferrite, and soft magnetic materials such as manganese zinc ferrite, and manganese ferrite materials. In addition, the methods and processes have been demonstrated for materials as soft as graphite and as hard as boron carbide. Micro components have been deposited in square, tapered and elongated shaped features with feature sizes as small as 10 &#x3bc;m in minimum dimensions and applied to flat and highly complex shaped surfaces. This process when combined with other cold spray manufacturing processes allows the total additive manufacturing of complete electronic, magnetic and other complex devices including multiple type of brittle functional materials.

Fine and micro feature cold spray deposition of semiconductors, magnetic and other brittle functional materials

Apparatus, and process for cold spray deposition of thermoelectric  semiconductor and other polycrystalline materials and method for making polycrystalline materials for cold spray deposition

A method of manufacturing fiber based and syntactic foam based composite type thermally insulating materials that retain high performance thermoelectric properties, and which can be used as thermoelectric generators or Peltier coolers for a wide range of industrial, commercial, residential and military applications.

Low thermal conductivity thermoelectric materials and method for making the same

A laser satellite communication system which avoids atmospheric, wind and turbulence effects. A satellite or high altitude platform communication system includes an earth-orbiting satellite or high altitude platform carrying a laser communications receiver and an acknowledgement transmitter. A ground terminal having a laser communications transmitter which is caused to continuously transmit large data block signals. When one block of data signals is received at the satellite or platform, an acknowledgement signal is sent to earth from the satellite or platform. The ground terminal receives the acknowledgement signal and causes the ground terminal laser communication transmitter to continuously transmit the next succeeding large block data signals. This process is repeated until all of the data has been received by the earth-orbiting satellite or high altitude platform, whereby all of the large data block signals are received by the laser communication receiver through scintillation windows in the atmosphere.

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Berryville, VA, United States of America

Richard C Thuss