Patent ID: 9705062
Date: 2017-07-11
CPC Classifications: H01L

Claim:
1. A method of fabricating a thermoelectric device intended for use at elevated temperatures in an oxidizing environment, the device comprising a plurality of like-shaped, electrically-interconnected, thermoelectric elements, each having opposed mounting faces spaced apart by a generally common length; and, a plurality of air impervious ceramic substrates comprising one low-temperature side substrate adapted for thermal communication with a heat sink, and opposing the low-temperature side substrate, a plurality of high temperature-side substrates adapted for thermal communication with a heat source, each of the substrates being thermally conducting and electrically insulating and each of the substrates incorporating one or more electrical interconnects, the method comprising: arranging the thermoelectric elements in a predetermined assembly pattern in which the thermoelectric elements are spaced apart with their opposed mounting faces in contact with the electrical interconnects on the opposing substrates to form an assembly, each of the elements and high temperature-side substrates being spaced apart and separated by gaps, and at least the high temperature-side substrates being shaped and arranged in a pattern having a perimeter adapted to promote thermal communication between the heat source and a heat source-contacting surface of the one or more substrates; positioning a continuous, upstanding, thin-walled, oxidation-resistant metal shield around the perimeter of the assembled high temperature substrates, the shield comprising a wall with a height and bounded by opposing first and second edges, the first edge being generally aligned with the heat source-contacting surface of the one or more high temperature-side substrates so that the first edge does not extend beyond the heat source-contacting substrate surface and the wall extending toward the low temperature-side substrate, the wall outlining an opening shaped and sized substantially like, but larger than, the perimeter of the assembled high temperature substrates so that a gap is formed between the shield wall and the assembled high temperature substrate perimeter, the wall having a height predetermined to maintain the second wall edge in spaced apart relation to the low temperature-side substrate to create a space between the low temperature-side substrate and the second wall edge; then sealing the gaps between the individual high temperature-side substrates and gap between the high temperature side substrate perimeter and the shield wall with an air-impervious vitreous enamel; and securing the second edge of the wall to the low temperature substrate with a polymer so that the thermoelectric elements are located in a sealed environment within an enclosure formed of the low temperature substrate, the high temperature substrates, the shield, the vitreous enamel and the polymer, all of which cooperate to exclude oxidizing gas from the enclosure interior.