Thin Thermoelectric Coating via PVD for Formability
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Solution Overview
Problem
Current thermoelectric devices face inefficiencies and high production costs due to complex manufacturing methods and limitations in applying thermoelectric composites, particularly in the formability and standardized sizes of prefabricated thermocouples, which hinder their industrial-scale adoption and commercialization.
Innovation Solution
A thin thermoelectric coating is developed using semiconductor 'p' and 'n' sub-layers interconnected in series with copper conducting elements, insulated by inorganic oxide layers, produced via PVD techniques like evaporation or magnetron sputtering, allowing for efficient electric energy generation without movable elements and noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If prefabricated thermocouples are used, then thermoelectric energy generation is achieved, but formability and adaptability are limited due to standardized sizes
Solution Approach 1:
The patent segments the thermoelectric functionality into thin-film layers that can be deposited on various substrates, allowing the system to adapt to different shapes and sizes while maintaining standardized manufacturing processes for the thermoelectric material layers themselves
Solution Approach 2:
The thin-film thermoelectric coating system is designed to be universally applicable to different substrates and geometries, enabling the same thermoelectric material technology to serve multiple applications with varying form factors without requiring different standardized thermocouple designs
2Loss of energy
If thermoelectric composites are applied comprehensively, then energy efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The patent replaces complex mechanical assembly of prefabricated thermocouples with a thin-film deposition process, where thermoelectric material layers are directly deposited onto substrates in a controlled vacuum environment, eliminating the need for mechanical joining and simplifying manufacturing
Solution Approach 2:
The patent changes the manufacturing parameters from macro-scale thermocouple assembly to micro-scale thin-film deposition, controlling material properties through deposition conditions rather than post-manufacturing assembly, thereby reducing manufacturing complexity while maintaining energy efficiency
3Power
If kinetic energy conversion methods are used, then electric energy generation is achieved, but device complexity and maintenance costs increase
Solution Approach 1:
The patent replaces mechanical kinetic energy conversion systems with a solid-state thermoelectric effect-based system, where electric energy is generated directly from temperature gradients across the thin-film thermoelectric layers without any moving parts, thereby eliminating maintenance requirements and reducing device complexity
Solution Approach 2:
The thermoelectric system generates electricity autonomously from waste heat or temperature differences in the environment, requiring no external mechanical input or complex control systems, and the thin-film structure enables direct integration with heat sources without additional mechanical components
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 solution enhances energy efficiency, reduces production costs, and increases reliability by generating electricity directly from temperature differences, suitable for powering electronic accessories or feeding back into the grid, while avoiding maintenance costs associated with kinetic energy conversion.
Implementation Method 1
The invention concerns a thin thermoelectric layer used in installations in which heat exchange takes place... Known are thermoelectric devices employing the Seebeck effect, which enable generation of electric energy. The devices contain thermoelectric technical means where the temperature difference between specific areas enables generation of electric energy.
Data Source
Figure 1
AI summary
A thin thermoelectric coating, the functioning of which is based on the Seebeck effect, having a thermoelectric layer with semiconductor elements 'p' and 'n' interconnected in series according to the invention is characterised in that it is produced under the PVD (Physical Vapour Deposition) technology, where the semiconductor elements of the thermoelectric layer (1) are formed into semiconductor sub-layers 'p' and 'n' which do not contact each other, the thickness (d1 of which ranges from 1µm to 10µm, where the sub-layers are interconnected in series with thin-layered conducting elements (2a, 2b) fitted with connection ends (4, 5) to evacuate the generated electric energy, where the thermoelectric layer (1) is insulated on both sides with layers (3a, 3b) of electrical insulator based on inorganic oxides.