Abstract: A thermoelectric device exhibiting both structural integrity and decreased stress across the device notwithstanding the application of thermally cycled temperature differentials thereacross includes, electrically interconnected thermoelectric elements and a rigidly affixed substrate. Thermal stress is relieved by using flexible conductors to interconnect the thermoelectric elements, and by the use of a flexile joint to attach a second substrate to the remainder of the device. Complete elimination of the second substrate may also be used to eliminate stress. Presence of the rigidly affixed substrate gives the device sufficient structural integrity to enable it to withstand rugged conditions.

Abstract: An apparatus for manufacturing thermoelectric devices includes two conductive strip receiving fixtures, a thermoelectric element receiving fixture and a u-shaped member. The conductive strip receiving fixtures act to retain the strips in proper registry during the processing steps of screen printing insulating material, or solder paste thereon as well as during attachment of thermoelectric elements thereto. The element receiving fixture is complemental with either of the strip receiving fixtures to maintain the elements in place during the coupling of the elements to the strips in one of the strip receiving fixtures. The strip receiving fixtures are complemental with the u-shaped member to complete the coupling of the elements to the strips such that the elements are coupled thermally in parallel and electrically in series. The u-shaped member also facilitates the introduction of a ceramic potting compound therebetween.Also disclosed is a method for manufacturing a thermoelectric device.

Abstract: A new and improved thermoelectric device of the type which provides electrical energy in response to a temperature gradient applied across the device exhibits both structural integrity and improved efficiency. The new thermoelectric device includes a plurality of thermoelectric elements, coupling means on opposite respective sides of the thermoelectric elements for interconnecting the elements electrically in accordance with a predetermined pattern, and encapsulant means including an encapsulant material covering the exposed surfaces of the thermoelectric elements. The encapsulant forms void spaces between the elements for providing effective thermal insulation between the elements and confining substantially all of the heat flow from the temperature gradient to through the elements. The coupling means includes electrically conductive plate segments for electrically interconnecting the thermoelectric elements.

Abstract: A new and improved thermoelectric device and a method of manufacturing same takes advantage of the anisotropy of the materials employed to provide a substantially increased power output over prior art devices. The individual thermoelectric elements are pressed using techniques such as those employed in powdered metallurgy and electrically coupled such that a current path is established through the elements in a direction substantially perpendicular to the direction of pressing.The method and device of the present invention also achieve a substantially thinner device than was previously possible with no concomitant sacrifice in individual thermoelectric element integrity or increased resistance of the electrical connections between the individual thermoelectric elements. The individual thermoelectric elements are dimensioned such that each has a first dimension substantially greater than either its second or third dimensions.

Abstract: The present invention provides a low cost, compact, efficient thermoelectric system which has no moving parts for converting waste heat into electrical energy. The system includes a plurality of heat pipes having at least one substantially planar sidewall and integral heat collecting fins. The planar sidewalls on the heat pipes enable broad surface thermal contact with thermoelectric devices. The heat pipes and integral heat collecting fins provide for the efficient collection and transmission of waste heat to the side of the thermoelectric devices contacting the heat pipes at a location outside of the flow of waste heat. The other side of each thermoelectric device is either water or air cooled to establish a temperature differential thereacross for the generation of electrical energy. The heat pipes are preferably generally rectangular in cross section to provide opposed substantially planar surfaces for making efficient, low heat loss, broad surface thermal contact with the thermoelectric devices.