초록 ▼

A method for fabricating a thermoelectric module with thermoelectric elements installed in an gapless eggcrate. This gapless eggcrate provides insulated spaces for a large number of p-type and n-type thermoelectric elements. The absence of gaps in the walls of the spaces virtually eliminates the pos

A method for fabricating a thermoelectric module with thermoelectric elements installed in an gapless eggcrate. This gapless eggcrate provides insulated spaces for a large number of p-type and n-type thermoelectric elements. The absence of gaps in the walls of the spaces virtually eliminates the possibility of interwall shorts between the elements. Thermoelectric elements, both p-type and n-type, are inserted into the insulated spaces in the gapless eggcrate to provide the desired thermoelectric effects . Electrical connections are established on both the hot and cold sides of the module to connect the thermoelectric elements in series or parallel as desired. Normally, most or all of the elements will be connected in series. In a preferred embodiment the gapless eggcrate is formed from a high temperature plastic. P-type thermoelectric material is extruded and then sliced to form p-type thermoelectric elements, and n-type thermoelectric material is extruded and sliced to form n-type thermoelectric elements. The thermoelectric elements are loaded in the eggcrate in an arrangement to put them all in series when a metal spray is applied to the hot and cold sides. Two electrical leads are applied and electrical connections on both the hot and cold sides are provided using a metal thermal spray technique. A thin layer of molybdenum is sprayed on one of the surfaces and then a coating of aluminum is sprayed over the molybdenum. These steps are repeated for the other side. Then the surfaces are ground down to expose the insulating eggcrate walls except where connections between the elements are desired. A seal is then applied over both the hot and cold surfaces. The seal preferably is very thin electrically insulating layer and over this layer a layer of aluminum is provided.

대표청구항 ▼

[ We claim:] [1.] A process for fabricating a thermoelectric module comprising the steps of:a) forming a gapless insulating eggcrate from an electrically insulating material, said eggcrate defining a plurality of thermoelectric spaces, each space having at least four insulating walls without gaps,b)

[ We claim:] [1.] A process for fabricating a thermoelectric module comprising the steps of:a) forming a gapless insulating eggcrate from an electrically insulating material, said eggcrate defining a plurality of thermoelectric spaces, each space having at least four insulating walls without gaps,b) fabricating a plurality of p-type thermoelectric elements each element being shaped to fit into one of said plurality of thermoelectric spaces,c) fabricating a plurality of n-type thermoelectric elements each element being shaped to fit into one of said plurality of thermoelectric spaces,d) inserting said plurality of p-type thermoelectric elements and said plurality of n-type thermoelectric elements into said plurality of thermoelectric spaces, ande) providing electrical connections on one side of said eggcrate, defining a hot side, and provide electrical connections on the other side defining a cold side, so as to connect a plurality of said elements in series and provide a thermoelectric module.