Abstract: Methods of fabricating a thermoelectric element include bonding at least one thermoelectric material leg to at least one of a header and an electrical connector using a direct bonding process. The direct bonding process may include liquid diffusion (e.g., brazing) or solid state diffusion bonding. The thermoelectric material leg may be directly bonded to the header or electrical connector without the use of a metal contact layer between the thermoelectric material leg and the header or electrical connector.

Abstract: A thermoelectric power generating module incorporates compliance into the module using a three-dimensional flexible connector. The flexible connector may relieve thermal stress and improve reliability for thermoelectric modules. In addition, the connector may provide a buffer layer (e.g., cushion) to damp mechanical vibrations. In further embodiments, a thermal interface structure for a thermoelectric device includes a thermally conductive body comprising a first compliant surface for directly interfacing with a first component of the thermoelectric device and a second compliant surface, opposite the first surface, for directly interfacing with a second component of the thermoelectric device.

Abstract: A thermoelectric power generating module incorporates compliance into the module using a three-dimensional flexible connector. The flexible connector may relieve thermal stress and improve reliability for thermoelectric modules. In addition, the connector may provide a buffer layer (e.g., cushion) to damp mechanical vibrations. In further embodiments, a thermal interface structure for a thermoelectric device includes a thermally conductive body comprising a first compliant surface for directly interfacing with a first component of the thermoelectric device and a second compliant surface, opposite the first surface, for directly interfacing with a second component of the thermoelectric device.

Abstract: A self-powered boiler comprising a burner that burns a fuel to produce a hot combustion product that is used to heat a fluid and a thermoelectric generator (TEG) system comprising a first side in thermal communication with the hot combustion product and a second side in thermal communication with a lower temperature region of the boiler, and a plurality of thermoelectric converters disposed therebetween for generating electric power, wherein the electric power generated by the TEG system is equal to or greater than a total electric power consumed by the boiler under normal operating conditions.

Abstract: Methods of fabricating a thermoelectric element with reduced yield loss include forming a solid body of thermoelectric material having first dimension of 150 mm or more and thickness dimension of 5 mm or less, and dicing the body into a plurality of thermoelectric legs, without cutting along the thickness dimension of the body. Further methods include providing a metal material over a surface of a thermoelectric material, and hot pressing the metal material and the thermoelectric material to form a solid body having a contact metal layer and a thermoelectric material layer.

Abstract: Methods of forming a conductive metal layers on substrates are disclosed which employ a seed layer to enhance bonding, especially to smooth, low-roughness or hydrophobic substrates. In one aspect of the invention, the seed layer can be formed by applying nanoparticles onto a surface of the substrate; and the metallization is achieved by electroplating an electrically conducting metal onto the seed layer, whereby the nanoparticles serve as nucleation sites for metal deposition. In another approach, the seed layer can be formed by a self-assembling linker material, such as a sulfur-containing silane material.

Abstract: Thermoelectric materials and methods of making thermoelectric materials having a nanometer mean grain size less than 1 micron. The method includes combining and arc melting constituent elements of the thermoelectric material to form a liquid alloy of the thermoelectric material and casting the liquid alloy of the thermoelectric material to form a solid casting of the thermoelectric material. The method also includes ball milling the solid casting of the thermoelectric material into nanometer mean size particles and sintering the nanometer size particles to form the thermoelectric material having nanometer scale mean grain size.

Abstract: Thermoelectric materials and methods of making thermoelectric materials having a nanometer mean grain size less than 1 micron. The method includes combining and arc melting constituent elements of the thermoelectric material to form a liquid alloy of the thermoelectric material and casting the liquid alloy of the thermoelectric material to form a solid casting of the thermoelectric material. The method also includes ball milling the solid casting of the thermoelectric material into nanometer mean size particles and sintering the nanometer size particles to form the thermoelectric material having nanometer scale mean grain size.

Abstract: Methods of forming a conductive metal layers on substrates are disclosed which employ a seed layer to enhance bonding, especially to smooth, low-roughness or hydrophobic substrates. In one aspect of the invention, the seed layer can be formed by applying nanoparticles onto a surface of the substrate; and the metallization is achieved by electroplating an electrically conducting metal onto the seed layer, whereby the nanoparticles serve as nucleation sites for metal deposition. In another approach, the seed layer can be formed by a self-assembling linker material, such as a sulfur-containing silane material.

Abstract: An apparatus includes an evacuated enclosure which comprises a tubular member extending along a longitudinal axis, a radiation absorber disposed in the enclosure and having a front surface and a back surface, the front surface being adapted for exposure to solar radiation so as to generate heat, at least one thermoelectric converter disposed in the enclosure and thermally coupled to the absorber, the converter having a high-temperature end to receive at least a portion of the generated heat, such that a temperature differential is achieved across the at least one thermoelectric converter, a support structure disposed in the enclosure coupled to a low-temperature end of the thermoelectric converter, where the support structure removes heat from a low-temperature end of the thermoelectric converter, and a heat conducting element extending between the support structure and the evacuated enclosure and adapted to transfer heat from the support structure to the enclosure.