Method and apparatus for fabricating a thermoelectric array
First Claim
1. A method of fabricating a thermoelectric device comprising:
- simultaneously depositing a plurality of first conductivity type thermoelements in a matrix member in a first spaced apart configuration;
simultaneously depositing a plurality of second conductivity type thermoelements in the matrix member in a second spaced apart configuration to form an alternately disposed array of first and second conductivity type thermoelements within the matrix member; and
depositing and securing in a predetermined pattern a plurality of conductive members on opposite sides of said array of first and second type thermoelements in order to connect the thermoelements in series.
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Accused Products
Abstract
A method and apparatus for fabricating a thermoelectric device includes forming a matrix board (12) with an array of orifices (100) formed therein. A plurality of P-type thermoelements (96) are formed and then a vacuum chuck (92) is utilized to dispose alternating ones of the elements (96) into the alternating ones of the orifices (100). A plurality of N-type elements (108) is formed and a vacuum chuck (104) is utilized to dispose alternating ones of the elements (108) into the remaining orifices (100) of the matrix (12). This forms an assembled array (52). A plurality of conductive tabs (114) is placed onto the P-type elements (98) and N-type elements (108) by a vacuum chuck (116). A second set of conductive tabs (120) is disposed on the opposite side of the assembled array by a vacuum chuck (124). A solder flow oven (54) and a solder flow oven (76) are utilized to reflow the solder on the tabs between the two operations. After connecting the tabs, the assembly (78) is moved to an epoxy station (80) to form an epoxy layer around the peripheral surfaces thereof to form a void (146) in the center portion thereof.
100 Citations
43 Claims
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1. A method of fabricating a thermoelectric device comprising:
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simultaneously depositing a plurality of first conductivity type thermoelements in a matrix member in a first spaced apart configuration; simultaneously depositing a plurality of second conductivity type thermoelements in the matrix member in a second spaced apart configuration to form an alternately disposed array of first and second conductivity type thermoelements within the matrix member; and depositing and securing in a predetermined pattern a plurality of conductive members on opposite sides of said array of first and second type thermoelements in order to connect the thermoelements in series. - View Dependent Claims (2, 3, 4, 5, 6)
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7. A method of fabricating a thermoelectric device comprising:
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forming a supporting matrix with a plurality of orifices therein in an array configuration; forming a plurality of thermoelectric elements of a first conductivity type dimension to fit in the orifices; disposing in one step the first type elements into alternate ones of the orifices in the matrix array; forming a plurality of thermoelectric elements of a second conductivity type dimensioned similar to the first type element; disposing in one step the second type elements into remaining ones of the orifices in the matrix array; and disposing and securing a plurality of conductive bridges on opposite sides of the array of first and second type elements in a pattern that connects the distal ends of adjacent ones of the first and second type elements together to form an electrical series connection. - View Dependent Claims (8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21)
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22. A method for fabricating a thermoelectric device, comprising:
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forming a supporting matrix with a plurality of orifices formed therein in an array configuration; forming a plurality of thermoelectric elements of a P-type conductivity dimensioned to fit in the orifices; arranging the P-type elements in a subarray, the subarray configured identical to the supporting matrix array; selecting alternate ones of the P-type elements in the subarray and transporting them as a single unit over the supporting matrix and simultaneously disposing the selected ones of the P-type elements in alternate ones of the orifices; forming a plurality of thermoelectric elements of an N-type conductivity; arranging the N-type elements in a subarray identical to the supporting matrix array; selecting alternate ones of the N-type elements in the subarray and transporting them as a single unit over the supporting matrix with the P-type elements therein and disposing the selected N-type elements into the remaining ones of the orifices; forming a first array of conductive bridges in a first predetermined pattern, the conductive bridges dimensioned to bridge between adjacent P and N-type elements on the distal ends thereof with respect to the supporting matrix; disposing in one step the first array of bridges on one side of the array of P and N-type elements, the first array bridging alternate pairs of P and N-type elements; securing the first array of bridges to the surfaces of the P and N-type elements; forming a second array of conductive bridges in a second predetermined pattern, the bridges therein dimensioned identical to the bridges in the first array; disposing in one step the second array of bridges on the opposite side of the array of the P and N-type elements, the pattern of the second array bridging between the pairs bridged by the first array of bridges such that a series circuit of alternating P and N-type elements is formed; and securing the second array of bridges to the respective surfaces of the P and N-type elements in the supporting matrix. - View Dependent Claims (23, 24, 25, 26)
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27. A method of fabricating a multi-stage thermoelectric device, comprising:
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forming a plurality of thermoelectric stages comprising the steps of; simultaneously depositing a plurality of first conductivity type thermoelements in a matrix member in a first spaced apart configuration, simultaneously depositing a plurality of second conductivity type thermoelements in the matrix member in a second spaced apart configuration to form an alternately disposed array of first and second conductivity type thermoelemenets within the matrix member, and depositing and securing in a predetermined pattern a plurality of conductive members on opposite sides of said array of first and second type thermoelements in order to connect the thermoelements in series; disposing at least one of the thermoelectric stages adjacent another one of the thermoelectric stages such that respective members are proximate each other; providing high thermal conductivity between the adjacent stages which electrically insulate the adjacent stages from each other; and attaching the adjacent stages together.
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28. A system for fabricating thermoelectric arrays comprising:
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means for separating a body of a first conductivity type material into a plurality of first type elements; a matrix defining a plurality of cells; first means for transporting selected ones of said first type elements to said matrix and simultaneously depositing said first type elements in alternate ones of said cells; means for separating a body of a second conductivity type material into a plurality of second type elements; second means for transporting selected ones of said second type elements to said matrix and simultaneously depositing said second type elements in alternate ones of said cells, wherein said matrix is filled with alternating first and second type elements; and means for electrically connecting contacts to said alternating first and second type elements to form a thermoelectric array. - View Dependent Claims (29, 30, 31, 32, 33, 34, 35, 36)
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37. A thermoelectric device comprising:
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a plurality of P-type and N-type conductivity elements arranged in an alternating array; contacts electrically connecting said elements together to form a series of P-N junctions; encapsulating material sealing the exterior surfaces of said elements to form a unitary body; and a central void area being defined within said unitary body and communicating with central portions of each of said elements, said void area having a low thermal conductance.
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38. A system for fabricating a thermoelectric device, comprising:
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a matrix having a plurality of orifices disposed in a planar array; means for forming a plurality of P-type conductivity thermoelectric elements; means for arranging said P-type elements in a subarray, said subarray similar to said matrix array; means for selectively transporting alternating ones of said P-type elements in said subarray to said matrix array and simultaneously depositing said selected P-type elements therein; means for forming a plurality of N-type conductivity thermoelectric elements; means for arranging said N-type elements into a subarray similar to said matrix array; means for selectively transporting alternating ones of said N-type elements to said matrix array and simultaneously depositing said selected N-type elements into the remaining ones of said orifices in said matrix array wherein selected P and N-type elements are disposed in said matrix array in an alternating pattern, said matrix array disposed about the midportions of said selected P and N-type elements; and means for electrically connecting alternating ones of said P and N-type elements in a series configuration to form a P-N thermoelectric device. - View Dependent Claims (39, 40, 41)
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42. A thermoelectric device, comprising:
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a first stage having a plurality of alternating P-type and N-type elements connected together in a series configuration to provide a thermoelectric effect; a second stage having a plurality of P-type and N-type thermoelements connected together in a series configuration to provide a thermoelectric effect; a thermally conducting plate disposed between said first and second stages; and means for attaching said first and second stages together with said plate disposed therebetween, said attaching means providing electrical insulation between said first and second stages. - View Dependent Claims (43)
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Specification