Additive Manufacturing of Thermoelectric Comb Structures
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Solution Overview
Problem
Current methods for manufacturing thermoelectric devices are complex, costly, and inefficient, struggling to achieve high output voltage and low electrical resistance while allowing for a large temperature difference between hot and cold sources, limiting their modularity and integration capabilities.
Innovation Solution
A method involving additive manufacturing to create thermoelectric devices with comb-shaped parts doped differently, assembled and electrically connected to form self-supporting structures with optimized branch connections, reducing the number of manufacturing steps and enhancing modularity and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional manufacturing methods are used for thermoelectric devices, then the manufacturing process is well-established, but the device complexity increases, manufacturing cost increases, and production time increases
Solution Approach 1:
The patent combines multiple manufacturing operations (additive deposition, doping, and structural formation) into a single integrated additive manufacturing process. The comb-shaped structures are built layer-by-layer with dopants incorporated during deposition, eliminating the need for separate doping steps and assembly operations required by conventional methods.
Solution Approach 2:
The additive manufacturing process serves multiple functions simultaneously: it deposits thermoelectric material, incorporates dopants, creates the comb-shaped geometry, and forms the structural framework all in one process. This multi-functional approach replaces the sequential specialized processes used in conventional manufacturing.
2Productivity
If conventional manufacturing methods are used for thermoelectric devices, then traditional processes are maintained, but production time increases and manufacturing cost increases
Solution Approach 1:
The additive manufacturing process performs preliminary actions by incorporating dopants and forming structural features during the deposition process itself, rather than requiring subsequent separate operations. The comb-shaped structures and doped regions are created simultaneously during the building process, eliminating post-processing time.
3Loss of substance
If conventional manufacturing methods are used for thermoelectric devices, then established techniques are applied, but material loss increases
Solution Approach 1:
The additive manufacturing process is self-service in that it deposits material only where needed to form the comb-shaped structures, with dopants incorporated precisely during the deposition process. This eliminates material waste associated with subtractive methods and separate doping operations that require additional material handling and disposal.
4Adaptability or versatility
If conventional manufacturing methods are used for thermoelectric devices, then traditional assembly processes are used, but integration capability decreases and modularity decreases
Solution Approach 1:
The comb-shaped structures are designed as modular segments that can be independently manufactured and then assembled. Each comb structure can serve as a discrete module, allowing for flexible integration into different device configurations and facilitating easier assembly and disassembly compared to conventional monolithic structures.
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 results in thermoelectric devices with high efficiency, low electrical resistance, and the ability to utilize large temperature differences, offering improved modularity, reduced material loss, and simplified integration, while being quicker and more economical to produce.
Implementation Method 1
In Seebeck mode, the thermoelectric effect is such that the at least one thermoelectric junction allows the generation of electrical energy when it is subjected to a temperature difference applied to the thermoelectric device between its first thermal side and its second thermal side
Implementation Method 2
In Peltier mode, the thermoelectric effect is such that the at least one thermoelectric junction allows the generation of thermal energy (difference in temperature between the first and second thermal sides) when it is subjected to electrical energy electrically supplying said at least one thermoelectric junction
Data Source
Figure 1~3
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Figure 6~8
AI summary
A method for manufacturing a thermoelectric device (1) is described in which a first part (10) formed from a first doped material and a second part (20) formed from a second doped material, each in the shape of a comb, are manufactured before being assembled and electrically connected. Then, the first base (11) of the first part (10) is sectioned into at least one first zone (14), and the second base (21) of the second part (20) is sectioned into at least one second zone (24). Each first branch (12) of the first part (10) and each second branch (22) of the second part (20), separated by a first zone (14), constitute respectively a first element (5) and a second element (6) of a thermoelectric junction (2), electrically connected to each other via the portion of the second base (21) that connects them.Furthermore, each first branch (12) and each second branch (22) separated by a second zone (24) constitute respectively a first element (5) and a second element (6) of a thermoelectric junction (2), electrically connected via the part of the first base (11) which connects them.