Thermoelectric Conversion Module Braided Wire Interconnects
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Solution Overview
Problem
Conventional tubular thermoelectric conversion modules face issues with reduced power generation capacity due to low thermal conductivity polymer material layers, inflexible insulating boards, and unreliable electric connections, limiting their applicability to various tube diameters and lengths.
Innovation Solution
A thermoelectric conversion module design featuring braided conductive wires connecting P-type and N-type elements in series, with one braided wire being longer than the other to prevent short-circuits and ensure reliable connections, allowing for flexible application to tubes of different diameters and lengths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If polymer material layers with low thermal conductivity are used to bond thermoelectric elements, then ease of manufacture is improved, but power generation capacity deteriorates due to reduced temperature difference
Solution Approach 1:
The patent removes the polymer material layer from the structure entirely, replacing it with a metal plate that has high thermal conductivity. This extraction of the problematic polymer layer eliminates the thermal resistance barrier while maintaining the bonding function through alternative means.
Solution Approach 2:
The patent changes the thermal conductivity parameter of the bonding material from low (polymer) to high (metal). By selecting a metal plate with thermal conductivity of 10-400 W/(m·K), the temperature difference across the bonding layer is minimized, thereby maximizing power generation capacity.
2Reliability
If insulating boards are used to support thermoelectric elements, then electrical insulation is improved, but adaptability to various tube diameters deteriorates due to inflexibility
Solution Approach 1:
The patent replaces rigid insulating boards with flexible insulating films that can conform to tubes of various diameters. The insulating film is wrapped around the metal plate, providing electrical insulation while allowing the structure to adapt to different curvature radii and tube sizes.
Solution Approach 2:
The patent creates a composite structure combining a metal plate (for thermal conductivity) with an insulating film (for electrical insulation and flexibility). This composite design achieves both electrical insulation and adaptability to various tube diameters simultaneously.
3Ease of manufacture
If conventional connection electrodes are used to connect P-type and N-type elements, then ease of manufacture is improved, but reliability deteriorates due to short-circuits and fractures
Solution Approach 1:
The patent introduces a dynamic compensation mechanism by making the second braided wire longer than the first braided wire. This length difference allows the connection structure to accommodate thermal expansion, contraction, and mechanical stress, preventing fractures and short-circuits while maintaining electrical connectivity.
Solution Approach 2:
The patent employs braided wires with built-in slack and loop structures that provide beforehand cushioning against mechanical stress and thermal cycling. The longer second wire acts as a buffer that absorbs expansion and contraction forces before they can cause damage to the connection.
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 design enhances power generation capacity, reliability of electric connections, and adaptability to various tube dimensions, preventing power loss from short-circuits and fractures, while maintaining high thermal conductivity.
Implementation Method 1
An element, in which a Peltier effect or a Seebeck effect is utilized, is used as a thermoelectric conversion element
Implementation Method 2
A material having a large performance index Z (=α2/ρK), which is expressed by a Seebeck coefficient 'α' which is of a constant unique to a substance, a specific resistance 'ρ' and thermal conductivity 'K'
Data Source
AI summary
The invention provides a thermoelectric conversion module, which can implement a high power generation capacity and high reliability of electric connection between thermoelectric conversion elements and meet various diameters and lengths of a tube as a heat source. The thermoelectric conversion module includes a straight-chain module unit. In the module unit, plural P-type elements and plural N-type elements, which are alternately arrayed, are electrically connected in series by a braided wire A and a braided wire B. The braided wire A connects one end surface of the P-type element and one end surface of the N-type element. The braided wire B connects the other end surface of the P-type element and the other end surface of the N-type element. The braided wire B is shorter than the braided wire A. The thermoelectric conversion module including only the module unit is spirally wound around a tube as a heat source.