3D Printed Thermoelectric Generator with Integrated Interconnects
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Solution Overview
Problem
The widespread adoption of thermoelectric generators is hindered by the cost and complexity of assembling devices that incorporate thermoelectric materials, as well as the inability to 3-D print the required thermally- and electrically-conducting materials, which are typically constructed from heterogeneous materials and require specific operational parameters.
Innovation Solution
The redesign of thermoelectric generators to simplify the number of distinct parts and materials, using 3-D printing to fabricate nearly-identical p-type and n-type legs and interconnects from the same material, eliminating contact resistance and enabling rapid, inexpensive fabrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If thermoelectric generators are assembled by hand using a variety of different materials, then the devices can be constructed with heterogeneous materials, but the manufacturing cost increases and device complexity increases
Solution Approach 1:
The patent combines multiple distinct components (thermoelectric legs, interconnects, and substrates) into a single integrated 3-D printed structure. This merging eliminates the need for manual assembly of heterogeneous materials while maintaining the functional benefits of material diversity through digital design and multi-material printing capabilities.
Solution Approach 2:
The 3-D printed structure serves multiple functions simultaneously: it provides structural support, electrical conduction, and thermal management all in one component. This multi-functionality replaces the need for separate specialized components made from different materials, reducing assembly complexity while maintaining adaptability.
2Adaptability or versatility
If thermoelectric generators are assembled by hand using a variety of different materials, then the devices can be constructed with heterogeneous materials, but the manufacturing cost increases
Solution Approach 1:
The patent changes the manufacturing parameter from manual assembly to automated 3-D printing. This parameter change enables the production of complex heterogeneous structures at lower cost by eliminating labor-intensive assembly processes and reducing material waste through precise digital fabrication.
Solution Approach 2:
The patent replaces the mechanical assembly process with a digital fabrication process. Instead of manually joining components through mechanical means, the design is directly manufactured using 3-D printing technology, substituting mechanical assembly with automated additive manufacturing.
3Adaptability or versatility
If traditional assembly methods are used, then heterogeneous materials can be incorporated, but reliability and reproducibility decrease
Solution Approach 1:
The patent uses digital 3-D printing to create precise copies of the thermoelectric device design. This digital copying process ensures that each device is manufactured with exact specifications, eliminating the variability and errors associated with manual assembly while maintaining the ability to incorporate heterogeneous materials through digital material selection.
4Adaptability or versatility
If traditional assembly methods are used, then heterogeneous materials can be incorporated, but reproducibility decreases
Solution Approach 1:
The patent replaces manual mechanical assembly with automated 3-D printing technology. This substitution ensures that each device is manufactured with consistent precision and material properties, dramatically improving reproducibility while maintaining the capability to incorporate heterogeneous materials through digital design and material selection.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for the mass production of thermoelectric generators with improved electrical conductivity and reduced manufacturing costs, facilitating their application in various fields such as home heating, automotive power, and aerospace.
Implementation Method 1
The n-type and p-type legs are each 3-D printed as a separate, single, and nearly-identical component from an electrically-conducting material, thereby eliminating contact resistance
Implementation Method 2
thermoelectric materials, which can generate electricity from low-level temperature differences
Data Source
AI summary
This disclosure relates to methods for manufacturing devices capable of functioning as thermoelectric generators and related objects by the process of additive manufacturing or by 3-D printing or by casting. This disclosure also particularly relates to the uses of the thermoelectric generators and related objects produced by these methods.