Thermoelectric Generation Module Adhesion Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Thermoelectric conversion layers in existing thermoelectric generation modules are prone to peeling off from electrodes or conductive layers when the substrate is bent, due to inadequate adhesion, leading to flexibility and durability issues.
Innovation Solution
A thermoelectric generation module design where a resin-made thermoelectric conversion layer adheres to a resin-made base material around the electrodes, excluding the connection points for wiring, with an easy adhesion layer or conductive resin layer enhancing the adhesion, and the layer's width being wider than its thickness to improve bonding strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the thermoelectric conversion layer is formed only on the electrode, then the manufacturing process is simple, but the adhesion between the thermoelectric conversion layer and the base material is poor, causing peeling when bent
Solution Approach 1:
The patent extends the thermoelectric conversion layer from a one-dimensional formation (only on the electrode) to a two-dimensional formation (on both the electrode and the surrounding base material). This dimensional expansion ensures that when the module is bent, the thermoelectric conversion layer remains adhered to the base material through the surrounding regions, preventing peeling while maintaining manufacturing simplicity through a single coating process.
2Adaptability or versatility
If the thermoelectric conversion layer is made thin to improve flexibility, then the module can be bent more easily, but the adhesion strength is reduced, causing peeling
Solution Approach 1:
By expanding the thermoelectric conversion layer to cover the surrounding base material area, the patent increases the total adhesion area in the planar dimension. This allows the layer to remain thin for flexibility while compensating for reduced thickness-based adhesion strength through increased lateral coverage, ensuring the layer remains adhered during bending.
Solution Approach 2:
The patent changes the geometric parameters of the thermoelectric conversion layer by extending its lateral dimensions beyond the electrode boundaries. This parameter change increases the surface area in contact with the base material, providing sufficient adhesion strength even when the layer thickness is reduced to maintain flexibility.
3Ease of operation
If the thermoelectric conversion layer adheres to the electrode only, then the wiring connection is easy, but the layer peels off during bending
Solution Approach 1:
The patent segments the adhesion function into two distinct zones: the electrode region for electrical connection and the surrounding base material region for mechanical anchoring. This segmentation allows the thermoelectric conversion layer to maintain easy wiring connection at the electrode interface while simultaneously achieving structural stability through adhesion to the surrounding base material during bending.
Solution Approach 2:
The patent applies local quality by giving different regions of the thermoelectric conversion layer different functional roles: the portion over the electrode provides electrical connectivity, while the portion extending to the surrounding base material provides mechanical anchoring and prevents peeling during bending, thus optimizing both wiring ease and structural integrity.
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 design significantly enhances the adhesion force between the thermoelectric conversion layer and the base material, improving the module's flexibility and resistance to bending, thermal expansion, and thermal shrinkage, thereby providing a reliable and durable thermoelectric generation module.
Implementation Method 1
A thermoelectric conversion material that allows mutual conversion between heat energy and electric energy is used for a thermoelectric conversion element
Data Source
AI summary
A thermoelectric generation module having: a base material; a plurality of electrodes disposed on the base material; and a thermoelectric conversion layer that coats each of the electrodes individually leaving a portion of the electrode to which a wiring is to be connected, wherein the thermoelectric conversion layer adheres to the base material around the electrode excluding the portion of the electrode to which the wiring is to be connected.