Thin-Film Thermoelectric Modules for High-Voltage Power Generation
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Solution Overview
Problem
Conventional thermoelectric devices have limited efficiency and size constraints, making them unsuitable for producing high-voltage power in compact forms, especially for applications requiring small packages and operating at ambient temperatures with minimal temperature gradients.
Innovation Solution
Development of thin-film thermoelectric modules with high length-to-area ratios, utilizing sputter-deposited BixTey and SbxTey alloys on flexible substrates, allowing for efficient conversion of thermal energy to electrical energy even with small temperature differences, and integration with heat pipes and interfacing electronics for enhanced power generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional thermoelectric devices use high ZT materials, then conversion efficiency is improved, but device size and flexibility are compromised
Solution Approach 1:
The patent applies thin-film deposition techniques to create thermoelectric devices with flexible substrates. The thermoelectric materials are deposited as thin films rather than using bulk materials, enabling the device to be flexible and compact while maintaining functional performance. This directly addresses the contradiction by allowing high efficiency materials to be used in a thin, flexible format suitable for small device packages.
Solution Approach 2:
The patent changes the physical state and dimensions of the thermoelectric materials by depositing them as thin films with controlled thickness and morphology. By altering the film thickness, surface area, and structural parameters during deposition, the device achieves both high conversion efficiency and compact size, resolving the contradiction between efficiency and device volume.
2Volume of moving object
If thermoelectric devices are made compact, then device size is reduced, but voltage output and power generation capability deteriorate
Solution Approach 1:
The patent increases the length-to-area ratio of the thermoelectric elements by utilizing thin-film deposition, which extends the effective length of the thermoelectric path in a compact footprint. This dimensional optimization allows the device to generate higher voltages despite its small size, as voltage is proportional to the length-to-area ratio in thermoelectric devices.
Solution Approach 2:
The patent uses composite thin-film structures with optimized material compositions to enhance power generation in compact devices. By combining different materials and optimizing their interfaces in the thin-film architecture, the device achieves high voltage output despite the reduced size, resolving the contradiction between compact form factor and power generation capability.
3Adaptability or versatility
If thin-film materials are used to enable flexible substrates, then device flexibility and compactness are improved, but thermoelectric figure of merit ZT deteriorates
Solution Approach 1:
The patent employs thin-film deposition on flexible substrates to achieve both flexibility and acceptable ZT values. By optimizing the thin-film structure, composition, and deposition conditions, the device maintains sufficient thermoelectric performance while enabling flexible and compact applications, thus resolving the contradiction between adaptability and energy conversion efficiency.
Solution Approach 2:
The patent optimizes multiple parameters including film thickness, deposition temperature, material composition, and microstructure to maximize ZT values in thin-film configurations. These parameter optimizations allow the device to achieve both substrate flexibility and improved thermoelectric performance, resolving the contradiction between adaptability and energy loss.
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 enables the production of μW to W power supplies with voltages greater than 1 V from small temperature differences, providing reliable and efficient power in compact formats suitable for remote and inaccessible locations, as well as large-scale sensor applications.
Implementation Method 1
TE power sources generate electric power based on creating a thermal gradient across the thermocouples of the thermopile. The TE power source operates to convert the thermal energy to electric power by accepting thermal energy on a 'hot' side or junction, passing it through the thermopile and rejecting heat to a 'cold' side or junction.
Implementation Method 2
The TE power source operates to convert the thermal energy to electric power by accepting thermal energy on a 'hot' side or junction, passing it through the thermopile and rejecting heat to a 'cold' side or junction.
Implementation Method 3
Development of thin-film thermoelectric modules with high length-to-area ratios, utilizing sputter-deposited BixTey and SbxTey alloys on flexible substrates
Data Source
AI summary
High performance thin film thermoelectric couples and methods of making the same are disclosed. Such couples allow fabrication of at least microwatt to watt-level power supply devices operating at voltages greater than one volt even when activated by only small temperature differences.