Self-Corrugating Laminates With Staggered Bond Lines for Rigid Thermoelectrics
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Solution Overview
Problem
Current laminate technologies face challenges in producing rigid, functional, and easily producible structural panels that can be shipped as films and expanded into structural and/or functional corrugates, with conventional shrinkable materials being unsuitable for demanding applications requiring regular structural corrugations.
Innovation Solution
Self-corrugating laminates with upper and lower shrinkable film layers and a non-shrinkable core, where the bond lines between the shrinkable film layers and the core are staggered, allowing for structural corrugations to form upon shrinkage, with a corrugation ratio between 0.02 and 0.9, and an aspect ratio of 0.1 to 0.8, enabling the creation of thermoelectric devices or modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional shrinkable materials are used to form corrugations, then the materials can be easily shrunk and contracted, but the resulting structures lack structural rigidity and cannot form regular structural corrugations
Solution Approach 1:
The patent uses a composite laminate structure consisting of a shrinkable polymer layer bonded to a rigid core material (such as metal, plastic, or paper). This composite construction allows the shrinkable layer to provide the shrinking function while the rigid core maintains structural integrity and forms regular structural corrugations when shrunk, resolving the contradiction between ease of shrinking and structural rigidity
Solution Approach 2:
The patent applies different material properties to different layers of the laminate: the outer shrinkable layer provides flexibility and shrinking capability, while the inner rigid core provides structural support and rigidity. This local differentiation of material qualities allows each layer to perform its specific function optimally, enabling both easy shrinking and structural rigidity
2Strength
If labor-intensive processes like thermoforming and bonding are used, then structural panels can be produced, but the production process becomes complex and time-consuming
Solution Approach 1:
The patent pre-bonds the shrinkable layer to the rigid core in a flat, uncurred state during manufacturing. This preliminary bonding eliminates the need for complex post-assembly operations, as the structural form is achieved automatically when the pre-bonded laminate is shrunk, thereby reducing process complexity while maintaining structural integrity
Solution Approach 2:
The patent extracts the complex forming operations from the manufacturing process by using a pre-bonded laminate that automatically forms the desired corrugated structure upon shrinking. This eliminates the need for separate thermoforming and bonding steps, simplifying the overall process while maintaining structural quality
3Strength
If parts are produced as bulky three-dimensional structures, then structural functionality is achieved, but shipping and packaging become difficult and costly
Solution Approach 1:
The patent creates a dynamic structure that transitions from a flat, low-volume state during shipping to a three-dimensional, high-volume corrugated structure during use. The shrinkable laminate allows the product to be compact for transport and then automatically expand to its functional form when activated, resolving the contradiction between structural functionality and shipping efficiency
4Strength
If the core material is made rigid to provide structural support, then structural integrity is improved, but the material becomes difficult to modify and introduce functionality into
Solution Approach 1:
The patent assigns different functional roles to different layers: the rigid core provides structural support while the outer shrinkable layer serves as the functional interface that can be easily modified, printed, or equipped with thermoelectric elements. This local differentiation allows the rigid core to maintain structural integrity while the functional properties can be adapted through modifications to the shrinkable layer
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 solution allows for the production of rigid, functional panels that can be easily shipped and expanded into structural corrugates, providing structural integrity and thermal stability, suitable for thermoelectric devices or modules with controlled corrugation patterns.
Implementation Method 1
the shrinkable film layers are caused to shrink, the non-shrinkable film layer is thereby formed into structural corrugations
Data Source
AI summary
Self-corrugating laminates useful in the manufacture of thermoelectric devices are disclosed. The laminates include an upper and a lower shrinkable film layer and a non-shrinkable core with a thermoelectric pattern formed thereon bonded between said upper and lower shrinkable film along bond lines arranged parallel, substantially parallel, radially, or annularly. The bond lines that bond the upper shrinkable film layer to top surface of the nonshrinkable core are staggered relative to the bond lines that bond the lower shrinkable film layer to the bottom surface of the non-shrinkable core such that upon shrinkage of the shrinkable film layers, structural corrugations are formed in the non-shrinkable core. Thermoelectric modules or devices and methods for forming them from the self-corrugating laminates are also described.