High Temperature Thermoelectrics

Abstract

In accordance with one embodiment of the present disclosure, a thermoelectric device includes a plurality of thermoelectric elements that each include a diffusion barrier. The diffusion barrier includes a refractory metal. The thermoelectric device also includes a plurality of conductors coupled to the plurality of thermoelectric elements. The plurality of conductors include aluminum. In addition, the thermoelectric device includes at least one plate coupled to the plurality of thermoelectric elements using a braze. The braze includes aluminum.

1 - 20 . (canceled) 
     
     
         21 . A thermoelectric device comprising:
 a first set of plates comprising a first plurality of conductors directly bonded to the first set of plates, the first plurality of conductors consisting essentially of aluminum, the first set of plates being electrically insulative;   a second set of plates comprising a second plurality of conductors directly bonded to the second set of plates, the second plurality of conductors consisting essentially of aluminum, the first set of plates being electrically insulative;   a plurality of thermoelectric elements situated between the first set of plates and the second set of plates, the plurality of thermoelectric elements coupled to the first plurality of conductors and the second plurality of conductors; and   a plurality of brazes comprising aluminum, the plurality of brazes situated at interfaces between the plurality of thermoelectric elements and the first plurality of conductors.   
     
     
         22 . The thermoelectric device of  claim 21  wherein the plurality of thermoelectric elements comprises a diffusion barrier. 
     
     
         23 . The thermoelectric device of  claim 22  wherein the diffusion barrier comprises a refractory metal. 
     
     
         24 . The thermoelectric device of  claim 22  wherein the diffusion barrier comprises titanium. 
     
     
         25 . The thermoelectric device of  claim 21  wherein the first set of plates plate and the second set of plates comprise a material selected from the group consisting of: aluminum oxide and aluminum nitride. 
     
     
         26 . The thermoelectric device of  claim 21  wherein the plurality of brazes comprise aluminum silicon. 
     
     
         27 . The thermoelectric device of  claim 21  further comprising solder, the solder situated at interfaces between the plurality of thermoelectric elements and the second plurality of conductors; and wherein the second set of plates consists of one plate. 
     
     
         28 . A method of forming a thermoelectric device, comprising:
 directly bonding a first plurality of conductors on a first set of plates, the first plurality of conductors consisting essentially of aluminum, the first set of plates being electrically insulative;   directly bonding a second plurality of conductors on a second set of plates, the second plurality of conductors consisting essentially of aluminum, the first set of plates being electrically insulative;   applying a plurality of brazes on the first plurality of conductors, the plurality of brazes comprising aluminum;   situating a plurality of thermoelectric elements between the first set of plates and the second set of plates, the plurality of brazes situated at interfaces between the plurality of thermoelectric elements and the first plurality of conductors; and   coupling the first plurality of conductors and the second plurality of conductors to the plurality of thermoelectric elements.   
     
     
         29 . The method of  claim 28  further comprising applying a diffusion barrier to the plurality of thermoelectric elements. 
     
     
         30 . The method of  claim 29  wherein the diffusion barrier comprises a refractory metal. 
     
     
         31 . The method of  claim 29  wherein the diffusion barrier comprises titanium. 
     
     
         32 . The method of  claim 28  wherein the first set of plates and the second set of plates comprise a material selected from the group consisting of:
 aluminum oxide and aluminum nitride. 
 
     
     
         33 . The method of  claim 28  wherein the plurality of brazes comprise aluminum silicon. 
     
     
         34 . The method of  claim 28  further comprising adding solder to interfaces between the plurality of thermoelectric elements and the second plurality of conductors; and wherein the second set of plates consists of one plate. 
     
     
         35 . A thermoelectric generator comprising:
 a first set of plates comprising a first plurality of conductors directly bonded to the first set of plates, the first plurality of conductors consisting essentially of aluminum, the first set of plates being electrically insulative;   a second set of plates comprising a second plurality of conductors directly bonded to the second set of plates, the second plurality of conductors consisting essentially of aluminum, the first set of elates being electrically insulative;   a plurality of P-type and N-type thermoelectric elements situated between the first set of plates and the second set of plates, the plurality of thermoelectric elements coupled to the first plurality of conductors and the second plurality of conductors;   a plurality of brazes comprising aluminum, the plurality of brazes situated at interfaces between the plurality of thermoelectric elements and the first plurality of conductors; and   wherein the thermoelectric generator is configured to operate while the first set of plates is at a temperature above 300 degrees Celsius.   
     
     
         36 . The thermoelectric generator of  claim 35  wherein the plurality of thermoelectric elements comprises a diffusion barrier. 
     
     
         37 . The thermoelectric generator of  claim 36  wherein the diffusion barrier comprises a refractory metal. 
     
     
         38 . The thermoelectric generator of  claim 36  wherein the diffusion barrier comprises titanium. 
     
     
         39 . The thermoelectric generator of  claim 35  wherein the first set of plates and the second set of plates comprise a material selected from the group consisting of: aluminum oxide and aluminum nitride. 
     
     
         40 . The thermoelectric generator of  claim 35  wherein the plurality of brazes comprises aluminum silicon. 
     
     
         41 . The thermoelectric generator of  claim 35 , wherein the thermoelectric generator is configured to operate while the first set of plates is at a temperature above 500 degrees Celsius and wherein the second set of plates consists of one plate.