Thermoelectric Module With Non-Uniform Element Density
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Solution Overview
Problem
Conventional thermoelectric conversion modules experience inefficiencies in converting heat to power due to irregular temperature distribution across substrates, leading to varying power production among thermoelectric elements.
Innovation Solution
The module is designed with a central thermoelectric conversion element group densely packed between substrates and peripheral groups less densely packed, with different cross-sectional areas and arrangements to optimize heat transfer and mechanical strength, using multiple types of solder for connections and resin layers for insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thermoelectric conversion elements are uniformly distributed across the substrate, then manufacturing is simple, but temperature distribution irregularities cause varying power production and reduced efficiency
Solution Approach 1:
The patent applies local quality by dividing thermoelectric elements into two groups with different densities: a first group in the central region with higher density and a second group in the peripheral region with lower density. This non-uniform distribution compensates for temperature irregularities, ensuring that elements in different regions operate at comparable temperatures and produce power efficiently, thereby resolving the contradiction between manufacturing simplicity and power production efficiency.
2Productivity
If thermoelectric conversion elements are densely packed to maximize power output, then power production increases, but heat transfer uniformity and mechanical strength decrease
Solution Approach 1:
The patent segments the thermoelectric element distribution into two distinct zones: a central region with densely packed elements for maximum power output and a peripheral region with sparsely packed elements for maintaining mechanical strength and heat transfer uniformity. This segmentation allows the system to simultaneously achieve high productivity in the central region while preserving structural integrity and thermal performance in the peripheral region.
3Device complexity
If all thermoelectric elements operate at different temperatures due to substrate irregularities, then manufacturing is simple, but power production varies significantly among elements
Solution Approach 1:
The patent implements local quality by creating region-specific density patterns: higher density in the central substrate region and lower density in peripheral regions. This approach compensates for temperature variations caused by substrate irregularities, ensuring that thermoelectric elements across different locations operate under more uniform thermal conditions and produce consistent power, thereby improving reliability without significantly increasing device complexity.
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 configuration enhances the conversion of heat to power with reduced losses, increasing efficiency and mechanical strength while maintaining uniform characteristics across thermoelectric elements.
Implementation Method 1
thermoelectric conversion module 1 disposed in contact with heat generator 10 converts heat generated from heat generator 10 into power
Data Source
AI summary
A thermoelectric conversion module according to the present disclosure includes a first substrate, a second substrate, and a peripheral thermoelectric conversion element group and a central thermoelectric conversion element group, each of which groups is disposed between the first substrate and the second substrate, and contains a plurality of thermoelectric conversion elements. The peripheral thermoelectric conversion element group is disposed in an area including peripheries of the first substrate and the second substrate, and the central thermoelectric conversion element group is disposed closer to a center of the first substrate and a center of the second substrate than the peripheral thermoelectric conversion element group. The plurality of thermoelectric conversion elements of the central thermoelectric conversion element group are disposed more densely than the plurality of thermoelectric conversion elements of the peripheral thermoelectric conversion element group.