Flexible Thermoelectric Module Electrodes for Thermal Expansion
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Solution Overview
Problem
Thermoelectric conversion modules experience electrode separation and reliability issues due to thermal expansion, leading to variations in internal resistance and voltage when used in high-heat applications like engine exhaust systems.
Innovation Solution
A thermoelectric conversion module design featuring flexible third electrodes and a layered structure with a high thermal conductivity first covering layer and a lower thermal conductivity second covering layer to prevent electrode separation and enhance reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the substrate is made rigid to maintain structural stability, then manufacturing precision is improved, but thermal expansion causes distortion and electrode separation under high heat
Solution Approach 1:
The patent applies flexible substrates (principle 30) to replace rigid substrates, allowing the substrate to bend and expand with thermal changes without causing electrode separation. This resolves the contradiction by maintaining structural integrity through flexibility rather than rigidity, preventing distortion while preserving manufacturing precision.
Solution Approach 2:
The patent changes the physical parameter of the substrate from rigid to flexible (principle 35), fundamentally altering its mechanical properties to accommodate thermal expansion. This parameter change enables the substrate to adapt to temperature variations without distortion, maintaining both manufacturing precision and connection reliability.
2Temperature
If thermal conductivity is increased to improve heat dissipation, then temperature control is improved, but heat reaches electrodes causing separation
Solution Approach 1:
The patent applies local quality (principle 3) by creating a dual-layer covering structure where different regions have different thermal conductivity properties. The first covering layer has high thermal conductivity for heat dissipation, while the second covering layer has low thermal conductivity to protect electrodes from heat, allowing simultaneous temperature control and joint strength maintenance.
Solution Approach 2:
The patent uses composite materials (principle 40) in the dual-layer covering structure, combining materials with different thermal conductivity characteristics. This composite approach enables the system to achieve both effective heat dissipation through the first layer and heat protection for electrodes through the second layer, resolving the contradiction between temperature control and joint strength.
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
The module effectively prevents electrode separation and maintains high reliability across various use conditions by using flexible electrodes and thermally conductive-insulating layers, ensuring stable voltage output and increased joint strength.
Implementation Method 1
the first covering layer and the second covering layer contain a material functioning as a thermally-conductive material
Implementation Method 2
the second covering layer is lower in thermal conductivity than the first covering layer
Implementation Method 3
a module comprising thermoelectric conversion elements capable of converting thermal energy into electrical energy through the Seebeck effect
Data Source
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AI summary
The invention comprises a plurality of thermoelectric conversion elements arranged adjacent to each other, first electrodes joined to first ends of the thermoelectric conversion elements to electrically connecting the first ends of adjacent thermoelectric conversion elements, and second electrodes joined to opposite, second ends of the thermoelectric conversion elements to electrically connecting the second ends of adjacent thermoelectric conversion elements, wherein the thermoelectric conversion elements electrically connected by the first and second electrodes form at least one series circuit element, and third electrodes having flexibility are provided at ends of the series circuit element.