Thermoelectric Module Vertical Stacking for Power and Reliability
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Solution Overview
Problem
Existing thermoelectric conversion modules face challenges in achieving high output power and long-term reliability while maintaining flexibility, as widening the temperature difference often leads to increased electrical resistance and reduced elements per unit area.
Innovation Solution
A thermoelectric conversion module design featuring a substrate with thermally conductive and insulating portions, encapsulation layers with specific properties, and flexible components, allowing for stable power generation even under deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the temperature difference is widened to increase thermoelectric conversion efficiency, then the output power increases, but the electrical resistance of thermoelectric element materials increases and the number of elements per unit area decreases
Solution Approach 1:
The patent transitions from planar thermoelectric elements to vertically stacked three-dimensional structures. Multiple thermoelectric element stacks are arranged in the thickness direction of the substrate, enabling power generation in the vertical dimension while maintaining high element density per unit area. This resolves the contradiction by adding a spatial dimension rather than simply increasing temperature difference.
Solution Approach 2:
The thermoelectric conversion module is divided into multiple independent thermoelectric element stacks, each comprising alternating P-type and N-type thermoelectric elements. These segmented stacks are arranged in series between heat receiving and heat dissipating electrodes, allowing the system to achieve high output power through cumulative effect while maintaining reasonable electrical resistance in each individual element.
2Power
If the distance between metal layers is increased to widen temperature difference, then the thermoelectric conversion efficiency improves, but the number of elements per unit area becomes smaller
Solution Approach 1:
The patent arranges thermoelectric element stacks in the thickness direction of the substrate rather than spreading them out in the planar direction. This vertical stacking enables the system to achieve both adequate temperature difference across each element and high element density per unit area, as the element count increases through the vertical dimension without reducing planar density.
3Power
If the thermoelectric element material is thinned to widen temperature difference, then the thermoelectric conversion efficiency improves, but the electrical resistance increases
Solution Approach 1:
The patent divides the thermoelectric conversion function into multiple discrete stacks, each with optimized thickness. By segmenting the system into series-connected stacks rather than using a single thin layer, the design achieves adequate temperature gradient across each stack while maintaining lower electrical resistance through the series configuration and increased total element area.
Solution Approach 2:
The patent employs composite structures combining P-type and N-type thermoelectric materials in alternating layers within each stack. This composite arrangement optimizes the thermoelectric properties of individual elements, achieving high conversion efficiency without excessive thinning that would increase resistance. The composite structure allows each material to contribute its optimal properties to the overall system performance.
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 module achieves stable high output power and long-term reliability, with improved flexibility and efficient heat dissipation, suitable for various applications including waste heat recovery.
Implementation Method 1
one of the flexible substrates is put in a high-temperature state and the other of the flexible substrates is put in a low-temperature state, thereby creating a temperature difference in the planar direction of the thermoelectric conversion module. This creates an electromotive force in the thermoelectric conversion module.
Implementation Method 2
a first thermally conductive portion and a second thermally conductive portion that are located on the second main surface and that are adjacent to each other in a first direction orthogonal to a thickness direction of the substrate
Implementation Method 3
a thermally insulating member that is located on the second main surface, at least between the first thermally conductive portion and the second thermally conductive portion
Data Source
Figure 1(a)~1(b)
Figure 2(a)~2(b)
Figure 3(a)~3(b)
AI summary
A thermoelectric conversion module provided with: a substrate having a first main surface and a second main surface; a thermoelectric conversion portion located on the first main surface; an encapsulation layer located on the thermoelectric conversion portion; a first thermally conductive portion and a second thermally conductive portion located on the second main surface; and a thermally insulating member located on the second main surface. The thermoelectric conversion portion has a p-type thermoelectric conversion element and an n-type thermoelectric conversion element, a first end of the p-type thermoelectric conversion element contacts a first end of the n-type thermoelectric conversion element, the first thermally conductive portion overlaps with a second end of the p-type thermoelectric conversion element, the second thermally conductive portion overlaps with a second end of the n-type thermoelectric conversion element, the encapsulation layer has a thickness of at least 5 µm and at most 150 µm, a water vapor transmission rate of at most 100 g/(m2·day), an emissivity of at least 0.70 and at most 0.99, and a thermal conductivity of at least 0.01 W/mK and at most 50 W/mK.