Thermoelectric Module Electrode Penetration for Durability

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional thermoelectric modules have poor durability due to separation of bonding elements under heat and vibration, leading to deteriorated power generation performance when used in vehicle exhaust systems.

Innovation Solution

A thermoelectric conversion module with n-type and p-type thermoelectric materials alternately disposed and electrodes that pass through these materials to enhance coupling, improving durability and power generation by maintaining a temperature difference for efficient heat transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If bonding elements are used to connect thermoelectric conversion materials and electrodes, then the module can be assembled, but the durability deteriorates due to separation under heat and vibration

Engineering Contradiction:

ImprovedurabilityVSAvoidbonding surface stability

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The electrode and thermoelectric conversion material are merged into a single integrated component, eliminating the bonding interface that causes separation. The electrode is formed to directly contact and electrically connect with the thermoelectric conversion material without requiring separate bonding elements, thus resolving the durability issue caused by bonding surface separation under heat and vibration.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The electrode is pre-formed with a specific shape and structure before assembly, including protrusions that fit into grooves of the thermoelectric conversion material. This preliminary preparation ensures proper alignment and mechanical coupling is achieved during assembly without requiring additional bonding steps, preventing future separation under thermal and vibrational stress.

Inventive Principle:

Principle #10Preliminary action

2Productivity

If the thermoelectric module is disposed in the exhaust system to utilize waste heat, then power generation is enabled, but the durability decreases due to exposure to heat and vibration

Engineering Contradiction:

Improvepower generationVSAvoiddurability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The electrode and thermoelectric conversion material are integrated into a single component that can withstand harsh exhaust system conditions. This merged structure eliminates weak bonding interfaces, enabling the module to maintain durability while generating power from waste heat in the high-temperature, high-vibration exhaust environment.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If bonding elements are used to assemble the thermoelectric module, then assembly is achieved, but the power generation performance deteriorates due to bonding surface separation

Engineering Contradiction:

ImproveassemblyVSAvoidpower generation performance

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The electrode and thermoelectric conversion material are combined into a single integrated component, eliminating the need for separate bonding elements. This integration maintains power generation performance by preventing bonding surface separation while still enabling efficient assembly through the built-in mechanical coupling features such as protrusions and grooves.

Inventive Principle:

Principle #5Merging (Combining)

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 improves the durability and power generation performance of thermoelectric modules by ensuring robust electrode-thermoelectric material coupling, reducing heat loss, and maintaining effective heat transfer, even under harsh conditions.

Implementation Method 1

A thermoelectric module is used for a thermoelectric power generation system using a Seebeck effect of generating an electromotive force by use of a temperature difference between opposite surfaces thereof.

Methodology Applied

Scientific EffectSeebeck effect: Seebeck Effect

Implementation Method 2

a high temperature side electrode that electrically connects the corresponding n type thermoelectric conversion material and the corresponding p type thermoelectric conversion material to transfer heat obtained from a heat source to the plurality of thermoelectric conversion materials

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS10971671B2Thermoelectric conversion module and vehicle including the same

Publication Date: 2021.04.06 HYUNDAI MOTOR CO LTD

AI summary

A thermoelectric conversion module may include a plurality of n type thermoelectric conversion materials and a plurality of p type thermoelectric conversion materials that are disposed alternately, and a plurality of electrodes that connects the plurality of thermoelectric conversion material disposed alternately on one side and on an opposite side alternately, wherein the plurality of electrodes includes a first electrode configured to electrically connect the n type thermoelectric conversion material and the p type thermoelectric conversion material by penetrating the n type thermoelectric conversion material and the p type thermoelectric conversion material to transfer heat obtained from a heat source to the plurality of thermoelectric conversion materials.