Abstract: Thermoelectric devices have an electrically conductive connector for connecting thermoelectric modules. The electrically conductive connector is a compliant mechanism having a first connecting region and a second connecting region that are rigid bodies and an elastically deformable region that is a flexible member positioned between the first and second connecting regions. The electrically conductive compliant mechanism connector enables facile manufacture and assembly of thermoelectric devices of various sizes and shapes that are conformable to irregularly shaped objects and body parts.

Abstract: The invention relates to the field of thermoelectric compositions and devices. Thermoelectric compositions comprise thermoelectric material in a flexible membrane that comprises structural material and voids. Thermoelectric subassemblies comprise thermoelectric material and electrical contact material along and on and surrounding structural material of the flexible membrane. Thermoelectric subassemblies can comprise thermoelectric elements positioned end-to-end in a flexible membrane that can be bent and positioned in a housing that can be adapted to accommodate various types of thermoelectric devices. Methods for making and using thermoelectric compositions, subassemblies, and devices are described.

Abstract: The invention relates to the field of thermoelectric compositions and devices. Thermoelectric compositions comprise thermoelectric material in a flexible membrane that comprises structural material and voids. Thermoelectric subassemblies comprise thermoelectric material and electrical contact material along and on and surrounding structural material of the flexible membrane. Thermoelectric subassemblies can comprise thermoelectric elements positioned end-to-end in a flexible membrane that can be bent and positioned in a housing that can be adapted to accommodate various types of thermoelectric devices. Methods for making and using thermoelectric compositions, subassemblies, and devices are described.

Abstract: A thermoelectric half-Heusler material comprising niobium (Nb), iron (Fe) and antimony (Sb) wherein the material comprises grains having a mean grain size less than one micron. A method of making a nanocomposite half-Heusler thermoelectric material includes melting constituent elements of the thermoelectric material to form an alloy of the thermoelectric material, comminuting (e.g., ball milling) the alloy of the thermoelectric material into nanometer scale mean size particles, and consolidating the nanometer size particles to form the half-Heusler thermoelectric material comprising at least niobium (Nb), iron (Fe) and antimony (Sb) and having grains with a mean grain size less than one micron.

Abstract: A thermoelectric half-Heusler material comprising niobium (Nb), iron (Fe) and antimony (Sb) wherein the material comprises grains having a mean grain size less than one micron. A method of making a nanocomposite half-Heusler thermoelectric material includes melting constituent elements of the thermoelectric material to form an alloy of the thermoelectric material, comminuting (e.g., ball milling) the alloy of the thermoelectric material into nanometer scale mean size particles, and consolidating the nanometer size particles to form the half-Heusler thermoelectric material comprising at least niobium (Nb), iron (Fe) and antimony (Sb) and having grains with a mean grain size less than one micron.

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 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: 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.