Energy harvesting for wearable technology through a thin flexible thermoelectric device

• US 10,141,492 B2
• Filed: 05/14/2015
• Issued: 11/27/2018
• Est. Priority Date: 05/14/2015
• Status: Active Grant

• Current Assignee: Nimbus Materials Inc
• Original Assignee: Nimbus Materials Inc
• Inventors: Kasichainula, Sridhar
• Primary Examiner(s): Baumann, Liesl C
• Application Number:
  US14/711,810
• Publication Number:
  US 20160336501A1
• Time in Patent Office: 1,293 Days
• Field of Search: 136200-242
• CPC Class Codes: H10N 10/01 Manufacture or treatment
• CPC Class Codes: H10N 10/13 characterised by the heat-exchanging means at the junction
• CPC Class Codes: H10N 10/17 characterised by the structure or configuration of the cell or thermocouple forming the device

Abstract

A method and/or apparatus of energy harvesting for wearable technology through a thin flexible thermoelectric device is disclosed. A lower conduction layer is deposited onto a lower dielectric layer. An active layer, comprising at least one thin film thermoelectric conduit and a thermal insulator, is above the lower conduction layer. An internal dielectric layer is deposited above the active layer, and conduit holes are drilled above each thermoelectric conduit. An upper conduction layer and upper dielectric layer are deposited, connecting the thermoelectric conduits in series. The resulting flexible thermoelectric device generates a voltage when exposed to a temperature gradient.

Claims

1. A flexible thermoelectric device, comprising:

a lower dielectric layer comprising flexible material to provide structure to the flexible thermoelectric device;

a lower conduction layer comprising a plurality of electrically conductive pads disposed directly on and across a surface of the lower dielectric layer, the plurality of electrically conductive pads comprising a plurality of N-designated conductive pads and a plurality of P-designated conductive pads, where the plurality of electrically conductive pads are arranged in pairs such that each pair comprises one N-designated conductive pad of the plurality of N-designated conductive pads and one P-designated conductive pad of the plurality of P-designated conductive pads that are adjacent to one another across the surface of the lower dielectric layer, where the N-designated conductive pad and the P-designated conductive pad in each pair are electrically coupled to one another through an electrically conductive lead extending between the N-designated conductive pad and the P-designated conductive pad adjacent to one another in the pair, the electrically conductive lead extending across the surface of the lower dielectric layer, being parallel to lengths of the N-designated conductive pad and the P-designated conductive pad in the pair, and being narrower in width compared to widths of the N-designated conductive pad and the P-designated conductive pad in the pair, where the widths of the N-designated conductive pad and the P-designated conductive pad are a dimension perpendicular to the length thereof;

a plurality of N-type thin film thermoelectric conduits, each N-type thin film thermoelectric conduit on top of a respective N-designated conductive pad of the plurality of N-designated conductive pads, each N-type thin film thermoelectric conduit having a top surface and a bottom surface, where the bottom surface directly contacts the respective N-designated conductive pad, and the top surface is opposite to the bottom surface;

a plurality of P-type thin film thermoelectric conduits, each P-type thin film thermoelectric conduit on top of a respective P-designated conductive pad of the plurality of P-designated conductive pads, each P-type thin film thermoelectric conduit having a top surface and a bottom surface, where the bottom surface directly contacts the respective P-designated conductive pad, and the top surface is opposite to the bottom surface;

an internal dielectric layer comprising a flexible dielectric material extending across the top surfaces of all the N-type thin film thermoelectric conduits and all the P-type thin film thermoelectric conduits, the internal dielectric layer being electrically insulating, and a surface of the internal dielectric layer being parallel to the top surfaces of each N-type thin film thermoelectric conduit and each P-type thin film thermoelectric conduit;

a thermal insulator to fill a space around each N-type thin film thermoelectric conduit and each P-type thin film thermoelectric conduit, the thermal insulator and the internal dielectric layer being laminated on top of the N-type thin film thermoelectric conduits and the P-type thin film thermoelectric conduits;

a plurality of contact holes extending through the internal dielectric layer and the thermal insulator such that each contact hole extends through a thickness of the internal dielectric layer directly into a thickness of the thermal insulator, and ends on the top surface of the respective N-type thin film thermoelectric conduit or the respective P-type thin film thermoelectric conduit;

a plurality of electrically conductive contacts, each electrically conductive contact fills a respective contact hole of the plurality of contact holes such that each electrically conductive contact extends perpendicularly through the respective contact hole from the top surface of the respective N-type thin film thermoelectric conduit or the respective P-type thin film thermoelectric conduit, through the thermal insulator, and through the thickness of the internal dielectric layer, where each electrically conductive contact includes an outward extension that emerges outward from the respective contact hole above the internal dielectric layer;

a plurality of another electrically conductive leads, each of which bridges between the outward extension of a first respective electrically conductive contact of the plurality of electrically conductive contacts outwardly extending from the N-type thin film thermoelectric conduit on the N-designated conductive pad of a first pair of the pairs and the outward extension of a second respective electrically conductive contact of the plurality of electrically conductive contacts outwardly extending from the P-type thin film thermoelectric conduit on the P-designated conductive pad in a second pair of the pairs, where the first pair and the second pair are adjacent to each other, such that all N-type and P-type thin film thermoelectric conduits of the flexible thermoelectric device are connected in series by the electrically conductive lead in each pair and the another electrically conductive leads, each another electrically conductive lead being disposed directly on the top surface of the internal dielectric layer between the outward extension of the first respective electrically conductive contact and the outward extension of the second respective electrically conductive contact; and

an upper dielectric layer comprising flexible material on top of the plurality of another electrically conductive leads to provide structure to the flexible thermoelectric device,

wherein each N-type thin film thermoelectric conduit and each P-type thin film thermoelectric conduit comprises thermoelectric material no thicker than 50 microns, and

wherein the flexible thermoelectric device is bendable to fit a shape of a target platform in which the flexible thermoelectric device is used to harvest thermal energy.

2. The flexible thermoelectric device of claim 1, further comprising:

at least one barrier layer between at least one of;

different thermoelectric materials within at least one of each N-type thin film thermoelectric conduit and each P-type thin film thermoelectric conduit,

an electrically conductive pad of the plurality of electrically conductive pads and the respective N-type or P-type thin film thermoelectric conduit, and

an electrically conductive contact of the plurality of electrically conductive contacts and the respective N-type or P-type thin film thermoelectric conduit,

wherein the at least one barrier layer is electrically conductive and has a higher melting temperature than either of the substances being separated by the at least one barrier layer.

3. The flexible thermoelectric device of claim 1,

wherein at least one of the plurality of electrically conductive pads comprises at least one of a metal cladding, a vacuum deposited metal, a conductive paste, an electroplated layer, and a surface plating layer.

4. The flexible thermoelectric device of claim 1, wherein the flexible material of the lower dielectric layer is doped polyimide or a metal-clad layer.

5. The flexible thermoelectric device of claim 1, wherein the thermoelectric material of each N-type thin film thermoelectric conduit and each P-type thin film thermoelectric conduit is Bi₂Te₃, ZnSb, PbTe, Zn₄Sb₃, an AgPb₁₈SbTe₂₀ filled skutterudite, a Bi₂Te₃/Sb₂Te₃superlattice, PbSeTe/PbTe quantum dots, Si₁₋

xGe_x, CsBi₄Te₆, Yb_0.19Co₄Sb₁₂, or CeFe_4+xCo_xSb₁₂.

6. The flexible thermoelectric device of claim 1,

wherein at least one of the plurality of electrically conductive contacts comprises at least one of a conductive paste, an electroplated layer, and a surface plating layer.

7. An apparatus comprising:

a flexible thermoelectric device, comprising;

a lower dielectric layer comprising flexible material to provide structure to the flexible thermoelectric device;

a lower conduction layer comprising a plurality of electrically conductive pads disposed directly on and across a surface of the lower dielectric layer, the plurality of electrically conductive pads comprising a plurality of N-designated conductive pads and a plurality of P-designated conductive pads, where the plurality of electrically conductive pads are arranged in pairs such that each pair comprises one N-designated conductive pad of the plurality of N-designated conductive pads and one P-designated conductive pad of the plurality of P-designated conductive pads that are adjacent to one another across the surface of the lower dielectric layer, where the N-designated conductive pad and the P-designated conductive pad in each pair are electrically coupled to one another through an electrically conductive lead extending between the N-designated conductive pad and the P-designated conductive pad adjacent to one another in the pair, the electrically conductive lead extending across the surface of the lower dielectric layer, being parallel to lengths of the N-designated conductive pad and the P-designated conductive pad in the pair, and being narrower in width compared to widths of the N-designated conductive pad and the P-designated conductive pad in the pair, where the widths of the N-designated conductive pad and the P-designated conductive pad are a dimension perpendicular to the length thereof;

a plurality of N-type thin film thermoelectric conduits, each N-type thin film thermoelectric conduit on top of a respective N-designated conductive pad of the plurality of N-designated conductive pads, each N-type thin film thermoelectric conduit having a top surface and a bottom surface, where the bottom surface directly contacts the respective N-designated conductive pad, and the top surface is opposite to the bottom surface;

a plurality of P-type thin film thermoelectric conduits, each P-type thin film thermoelectric conduit on top of a respective P-designated conductive pad of the plurality of P-designated conductive pads, each P-type thin film thermoelectric conduit having a top surface and a bottom surface, where the bottom surface directly contacts the respective P-designated conductive pad, and the top surface is opposite to the bottom surface;

an internal dielectric layer comprising a flexible dielectric material extending across the top surfaces of all the N-type thin film thermoelectric conduits and all the P-type thin film thermoelectric conduits, the internal dielectric layer being electrically insulating, and a surface of the internal dielectric layer being parallel to the top surfaces of each N-type thin film thermoelectric conduit and each P-type thin film thermoelectric conduit;

a thermal insulator to fill a space around each N-type thin film thermoelectric conduit and each P-type thin film thermoelectric conduit, the thermal insulator and the internal dielectric layer being laminated on top of the N-type thin film thermoelectric conduits and the P-type thin film thermoelectric conduits;

a plurality of contact holes extending through the internal dielectric layer and the thermal insulator such that each contact hole extends through a thickness of the internal dielectric layer directly into a thickness of the thermal insulator, and ends on the top surface of the respective N-type thin film thermoelectric conduit or the respective P-type thin film thermoelectric conduit;

a plurality of electrically conductive contacts, each electrically conductive contact fills a respective contact hole of the plurality of contact holes such that each electrically conductive contact extends perpendicularly through the respective contact hole from the top surface of the respective N-type thin film thermoelectric conduit or the respective P-type thin film thermoelectric conduit, through the thermal insulator, and through the thickness of the internal dielectric layer, where each electrically conductive contact includes an outward extension that emerges outward from the respective contact hole above the internal dielectric layer;

a plurality of another electrically conductive leads, each of which bridges between the outward extension of a first respective electrically conductive contact of the plurality of electrically conductive contacts outwardly extending from the N-type thin film thermoelectric conduit on the N-designated conductive pad of a first pair of the pairs and the outward extension of a second respective electrically conductive contact of the plurality of electrically conductive contacts outwardly extending from the P-type thin film thermoelectric conduit on the P-designated conductive pad in a second pair of the pairs, where the first pair and the second pair are adjacent to each other, such that all N-type and P-type thin film thermoelectric conduits of the flexible thermoelectric device are connected in series by the electrically conductive lead in each pair and the another electrically conductive leads, each another electrically conductive lead being disposed directly on the top surface of the internal dielectric layer between the outward extension of the first respective electrically conductive contact and the outward extension of the second respective electrically conductive contact; and

an upper dielectric layer comprising flexible material on top of the plurality of another electrically conductive leads to provide structure to the flexible thermoelectric device,

wherein each N-type thin film thermoelectric conduit and each P-type thin film thermoelectric conduit comprises thermoelectric material no thicker than 50microns; and

a target platform to which the flexible thermoelectric device is adhered to by way of a thermal adhesive layer affixed to at least one of;

the upper dielectric layer and the lower dielectric layer of the flexible thermoelectric device,

wherein the flexible thermoelectric device is bendable to fit a shape of the target platform in which the flexible thermoelectric device is used to harvest thermal energy.

8. The apparatus of claim 7, wherein the target platform is one of:

a wearable device, a piece of clothing, a piece of jewelry, a sensor, a handheld device, and a building material.

9. The apparatus of claim 7, wherein the flexible thermoelectric device further comprises:

at least one barrier layer between at least one of;

different thermoelectric materials within at least one of each N-type thin film thermoelectric conduit and each P-type thin film thermoelectric conduit,

an electrically conductive pad of the plurality of electrically conductive pads and the respective N-type or P-type thin film thermoelectric conduit, and

an electrically conductive contact of the plurality of electrically conductive contacts and the respective N-type or P-type thin film thermoelectric conduit,

wherein the at least one barrier layer is electrically conductive and has a higher melting temperature than either of the substances being separated by the at least one barrier layer.

10. The apparatus of claim 7,

wherein at least one of the plurality of electrically conductive pads of the flexible thermoelectric device comprises at least one of a metal cladding, a vacuum deposited metal, a conductive paste, an electroplated layer, and a surface plating layer.

11. The apparatus of claim 7, wherein the flexible material of the lower dielectric layer of the flexible thermoelectric device is doped polyimide or a metal-clad layer.

12. The apparatus of claim 7, wherein the thermoelectric material of each N-type thin film thermoelectric conduit and each P-type thin film thermoelectric conduit is Bi₂Te₃, ZnSb, PbTe, Zn₄Sb₃, an AgPb₁₈SbTe₂₀ filled skutterudite, a Bi₂Te₃/Sb₂Te₃ superlattice, PbSeTe/PbTe quantum dots, Si₁₋

xGe_x, CsBi₄Te₆, Yb_0.19Co₄Sb₁₂, or CeFe_4+xCo_xSb₁₂.

13. The apparatus of claim 7,

wherein at least one of the plurality of electrically conductive contacts of the flexible thermoelectric device comprises at least one of a conductive paste, an electroplated layer, and a surface plating layer.