High temperature compact thermoelectric module with gapless eggcrate

Abstract

A high-temperature thermoelectric module. The module includes a two part molded egg-crate for holding in place and providing insulation and electrical connections for a number of thermoelectric n-legs and p-legs. A first part of the egg-crate is comprised of a ceramic material capable of operation at temperatures in excess of 600° C. and a second part comprised of a thermoplastic material having very low thermal conductivity. In preferred embodiments the high temperature ceramic is zirconia and the thermoplastic material is DuPont Zenite. The thermoelectric legs are also comprised of high-temperature and low-temperature material. In preferred embodiments the high temperature thermoelectric material is lead telluride and the low temperature material is bismuth telluride. In preferred embodiments metal felt spacers are provided in each leg to maintain proper electrical contacts notwithstanding substantial temperature variations. Preferably the module is sealed in an inert gas filled insulating capsule.

1 . A high-temperature thermoelectric module comprising:
 A. a two-part molded egg-crate for holding in place and providing insulation and electrical connections for a number of thermoelectric n-legs and p-legs, wherein said egg-crate is comprised of:
 1) a hot side part comprised of a ceramic material capable of operation at temperatures in excess of 500° C. and 
 2) a cold side part comprised of a thermoplastic material having very low thermal conductivity. 
   B. a plurality of high-temperature thermoelectric n-legs and p-legs positioned in said egg-crate, at least a portion of which are electrically connected in series.   
   
   
       2 . The thermoelectric module as in  claim 1  wherein said ceramic material is stabilized zirconium oxide and said thermoplastic material is in the form of a liquid crystal polymer resin. 
   
   
       3 . The thermoelectric module as in  claim 2  wherein the cold side part and the hot side part are joined together at a tab and socket junction. 
   
   
       4 . The thermoelectric module as in  claim 3  wherein the module defines at least four outside walls and a large number of inside walls and the tab and socket junction includes tabs and sockets in the outside walls. 
   
   
       5 . The thermoelectric module as in  claim 4  wherein the tab and socket junction also includes tabs and sockets in at least a plurality of the inside walls. 
   
   
       6 . The thermoelectric module as in  claim 1  wherein the thermoelectric p-legs and n-legs are comprised of a lead telluride thermoelectric alloy. 
   
   
       7 . The thermoelectric module as in  claim 1  wherein the thermoelectric p-legs and n-legs are segmented legs, comprised of a high-temperature material and a low-temperature material. 
   
   
       8 . The thermoelectric module as in  claim 7  wherein high-temperature thermoelectric material is a lead telluride thermoelectric alloy and the low-temperature material is a bismuth telluride thermoelectric alloy. 
   
   
       9 . The thermoelectric module as in  claim 1  wherein metal felt spacers are provided in each leg to maintain proper electrical contacts notwithstanding substantial temperature variations. 
   
   
       10 . The thermoelectric module as in  claim 9  wherein the metal felt spacers are impregnated with an elastomer. 
   
   
       11 . The thermoelectric module as in  claim 10  wherein the elastomer is silicon rubber. 
   
   
       12 . The thermoelectric module as in  claim 1  wherein the module is sealed in an insulating capsule. 
   
   
       13 . The thermoelectric module as in  claim 1  wherein the module is combined with other similar modules to provide a thermoelectric generator. 
   
   
       14 . The thermoelectric module as in  claim 13  wherein the thermoelectric generator is adapted to provide electric power from the waste heat of a motor vehicle. 
   
   
       15 . The thermoelectric module as in  claim 1  wherein said n-legs are electrically connected to said p-legs at the hot side of the module with a lead telluride compatible hot conductor element. 
   
   
       16 . The thermoelectric module as in  claim 15  wherein the compatible hot conductor element is comprised of iron. 
   
   
       17 . The thermoelectric module as in  claim 15  wherein the egg-crate walls separating the n-legs from the p-legs are adapted to contact the hot conductor so that tellurium vapor is restrained from migrating to the n-leg. 
   
   
       18 . The thermoelectric module as in  claim 7  wherein the p-legs comprise a thin layer of PbSnMnTe or SnTe at their hot sides.