Thermoelectric Generator Support Structure Without Fragile Membranes
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Solution Overview
Problem
Existing thermoelectric generators suffer from structural weaknesses, particularly during the resin injection process in packaging, which can cause mechanical breakdown of membranes and result in a high number of rejects.
Innovation Solution
A thermoelectric generator design that includes a thermoelectric converter with a support body comprising a structural layer and a thermal insulation layer, and a thermal coupling structure that thermally couples the converter to a hot and a cold body, eliminating the need for membranes and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If membranes are used in thermoelectric generator packaging, then thermal coupling is achieved, but mechanical breakdown occurs during resin injection
Solution Approach 1:
The patent removes the membrane component entirely from the packaging structure. Instead of using a membrane that requires resin injection, the invention employs a cavityless support body where thermopiles are directly mounted, eliminating the source of mechanical breakdown while maintaining thermal coupling functionality through direct thermal paths.
Solution Approach 2:
The support body is divided into a structural layer and a thermal insulation layer with distinct functions. The structural layer provides mechanical support and thermal conduction paths, while the thermal insulation layer provides thermal isolation, allowing each layer to be optimized for its specific function without compromising the other.
2Temperature
If membranes with cavities are used, then thermal insulation is achieved, but structural weakness increases
Solution Approach 1:
The support body uses a composite structure with a structural layer (conductive material) and a thermal insulation layer (insulating material). This composite design provides both thermal insulation and structural integrity simultaneously, eliminating the need for cavity-based insulation that compromises mechanical strength.
Solution Approach 2:
Different regions of the support body have different thermal conductivities - the structural layer has high thermal conductivity for heat transfer paths, while the thermal insulation layer has low thermal conductivity for thermal isolation. This local differentiation of material properties achieves both insulation and strength requirements.
3Reliability
If resin injection is used for packaging, then encapsulation is achieved, but mechanical breakdown of membranes occurs
Solution Approach 1:
The invention eliminates the membrane component that is vulnerable to resin injection damage. By using a cavityless support body structure, the packaging process no longer involves injecting resin into confined spaces with delicate membranes, thereby removing the primary source of manufacturing defects and improving yield.
Solution Approach 2:
Instead of injecting resin into a cavity enclosed by membranes, the invention inverts the approach by providing structural support and thermal pathways through the support body itself, allowing packaging without the need for cavity-filling resin injection that damages membranes.
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 design enhances mechanical robustness, reduces the risk of mechanical breakdown, and simplifies the manufacturing process, leading to improved yield and efficiency in energy harvesting.
Implementation Method 1
the thermal insulation layer thermally insulates the thermopiles from the structural layer
Implementation Method 2
Thermoelectric generators or TEGs exploit the thermoelectric effect between pairs of different conductors in presence of a temperature difference between a hot body and a cold body to produce an electrical quantity
Data Source
AI summary
A thermoelectric generator includes a thermoelectric converter and a thermal coupling structure, configured to thermally couple the thermoelectric converter to a first body at a first temperature and to a second body at a second temperature, lower than the first temperature. The thermoelectric converter includes a support body, having a structural layer and a thermal insulation layer, and a plurality of thermopiles arranged on the thermal insulation layer and thermally coupled to the thermal coupling structure. The thermal insulation layer has a thickness such as to thermally insulate the thermopiles from the structural layer and the support body is continuous and without cavities between the thermopiles and a face of the structural layer opposite to the thermopiles.