Abstract:
The electrical junctions of either or both sides of a thermoelectric module are placed in direct thermal contact with a heat source or sink or a material to be thermally modified (that is, heated or cooled), thereby eliminating the conventional substrate typically found in such modules and its associated thermal resistance. In one embodiment, the conductive junction passes through a conduit carrying a material to be heated or cooled. In the conduit, the conductive material can be configured into an effective heat transfer shape such as a vane which extends through non-conducting conduit walls. In another embodiment, the geometry of the conductor forming the electrical junction forms a pipe or tube through which material to be heated or cooled is passed. A protection layer of high thermal conductivity can be applied to the conductive surfaces in order to prevent corrosion or short-circuiting of the device in applications where an electrolytic or ionic fluid is passed by the junction.

Description:
FIELD OF THE INVENTION 
     This invention relates to heat transfer devices and, more particularly, to thermoelectric heat transfer devices. 
     BACKGROUND OF THE INVENTION 
     Thermoelectric modules are solid-state devices that convert electrical energy to a temperature gradient by using an effect known as the “Peltier effect.” Alternatively, thermal energy can be applied to such devices by placing a temperature gradient across them to generate electrical energy due to an effect known as the “Seebeck effect.” 
     When an appropriate electrical voltage is applied, from a battery or other DC source, to a thermoelectric module, one side of the module becomes cold while the other side of the module becomes hot. The “hot” and “cold” sides of the module depend on the current flow through the device; if the voltage polarity across the module is reversed thereby causing a reverse in the current flow the module “cold” side will become the “hot” side and vice versa. Thermoelectric modules are typically used by placing them between a heat source and a heat sink, such as a liquid plate, a surface plate, or a convection heat sink. The thermoelectric module will absorb heat on its “cold” side from the heat source and transfer the heat to its “hot” side and to the heat sink. 
     A conventional thermoelectric module is composed of an array of thermoelectric elements called “dice” which are generally fabricated from Bismuth Telluride and are available in P-types and N-types. The P-type and N-type materials are alloys of Bismuth and Tellurium that have different free electron densities at the same temperature. P-type dice are composed of material having a deficiency of electrons while N-type dice are composed of a material having an excess of electrons. Most modules have an equal number of P-type and N-type dice and one die of each type sharing an electrical interconnection is known as a “couple.” When an electrical current flows through the couple, it attempts to establish a new equilibrium within the materials. The direction of the current will determine if a particular side will cool down or heat up. 
     The array of P-type and N-type thermoelectric elements are electrically connected in a series chain of couples with alternating element types connected by electrical junctions. When so connected, the electrical junctions form the hot and cold sides of the device with alternating junctions becoming hot and cold, respectively when electrical power is applied to the chain. 
     In order to form a compact and physically rugged module, the dice are conventionally sandwiched between two ceramic substrates that provide mechanical rigidity and electrical insulation. The P-type and N-type dice are connected electrically in series by electrically conductive materials, usually metal pads, plated on, or attached to, the ceramic substrates. The dice are generally soldered to the pads for mechanical strength. 
     Such a module is illustrated in FIGS. 1A and 1B, which are cross-sections and top views, respectively, of a thermoelectric module  100 . In FIG. 1A, the module  100  is shown sandwiched between a finned convection style heat sink  102  and a heat source  104 . In FIG. 1B, the heat sink  102  and the upper substrate  106  have been removed to expose the metal pads that interconnect the thermoelectric elements. 
     Three such elements  110 ,  112  and  114  are shown in Figure  1 A. As mentioned above, the elements are connected in couples such that P-type dice alternate with N-type dice. For example, thermoelectric elements  110  and  112  are electrically interconnected by electrical pad  116 . Similarly, elements  112  and  114  are connected by pad  120 . Pads  118  and  122  connect elements  110  and  114  to other elements (not shown.) 
     FIG. 1B shows a top view that has been exposed to illustrate the electrical interconnections. As shown pads  116 ,  120 ,  122 ,  124 ,  126 ,  128 ,  130  and  132  connect eight thermoelectric elements in series. Element  134  would also be connected by an electrical pad (not shown) to either another element or an electrical power source. This conventional construction is disclosed in several references including the “CRC Handbook of Thermoelectrics, and Thermoelectric Refrigeration” by H. J. Goldsmid. 
     While such devices work well, the efficiency is limited by the conventional construction. The most common type of material used to fabricate substrates  106  and  108  is 96% alumina. This material has poor thermal conductivity for example approximately 35 watts/m ° C. Since heat, which is transferred from the heat source  104  to the heat sink  102 , must pass through two substrates  108  and  106 , both of which have poor conductivity, the efficiency of the device is reduced. 
     Therefore, there is a need for a thermoelectric device with improved thermal efficiency. 
     SUMMARY OF THE INVENTION 
     In accordance with the principles of the invention, the electrical junctions of either or both sides of a thermoelectric module are placed in direct thermal contact with a heat source or sink or a material to be thermally modified (that is, heated or cooled), thereby eliminating the conventional substrate and its associated thermal resistance. An electrically conductive material such as copper, aluminum or any other known electrical conductor exhibiting relatively high thermal conductivity can be used as the electrical junction between a pair of thermoelectric elements and at the same time function as the transfer medium for the thermal energy produced by the elements. 
     In one embodiment, the conductive junction passes through a conduit carrying a material to be heated or cooled. In the conduit, the conductive material can be configured into an effective heat transfer shape such as a vane that extends through a non-conducting tube or pipe. 
     In another embodiment, the geometry of the conductor forming the electrical junction forms a pipe or tube through which material to be heated or cooled is passed. 
     The use of the inventive module eliminates the need for separate heat exchange devices such as heatsinks, liquid plates, etc., therefore reducing the size of the heat exchanger as well as increasing efficiency by eliminating interfaces between devices. 
     Additionally this invention can be highly effective in the transfer of waste heat into useable electrical energy. The reduced size and increased efficiency of this design can be effectively used in applications such as automotive exhaust pipes and radiators where the thermoelectric device is built into the apparatus. Many other uses could be considered including steam pipes, process piping, ventilation systems, etc. 
     In still another embodiment, a protection layer of high thermal conductivity can be applied to the conductive surfaces in order to prevent corrosion or short-circuiting of the device in applications where an electrolytic or ionic fluid is passed by the junction. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The above and further advantages of the invention may be better understood by referring to the following description in conjunction with the accompanying drawings in which: 
     FIG. 1A is a cross-sectional view of a conventional thermoelectric module illustrating the substrates, thermoelectric elements and connections. 
     FIG. 1B is a top view of the device shown in FIG. 1A with overlaying heat sink and top substrate removed in order to expose the electrical connections. 
     FIG. 2A is a front view of a first embodiment of the invention in which the conductive junctions of a thermoelectric module pass through a conduit carrying a material to be heated or cooled. 
     FIG. 2B is a side view of the embodiment illustrated in FIG. 2A showing the junctions passing through the conduit. 
     FIG. 2C is a top view of the embodiment illustrated in FIG. 2A showing the junctions passing through the conduit. 
     FIG. 3 is a perspective view of a system using several assemblies like those shown in FIGS. 2A-2C. 
     FIG. 4 is a perspective view of another embodiment of the invention in which the conductive junctions are configured as the walls of a conduit carrying a material to be heated or cooled. 
    
    
     DETAILED DESCRIPTION 
     FIGS. 2A,  2 B and  2 C show side, front and top views, respectively, of a first illustrative embodiment of the invention. In the orientation shown, the side view of FIG.  2 A and the front view of FIG. 2B correspond to the directions indicated by the section lines shown in the top view of FIG.  2 C. In this embodiment, a material to be heated or cooled passes, as indicated by arrow  201 , through a conduit  205  having top  202  and bottom  204  walls that are constructed of an electrically insulating material, such as a polymeric or fiber material. The conduit  205  also has end walls (not shown) that confine the fluid in the conduit. Embedded in (or alternatively mounted on the surface of) the top wall  202  is an alternating series of thermoelectric elements  206 ,  222 ,  230 , etc. On the opposite wall  204 , another alternating series of thermoelectric elements  208 ,  220 ,  232 , etc. are attached or embedded. 
     The elements are connected by electrical conductors to form a series connection with thermoelectric elements of P-type and N-type being connected in an alternating series in order to form a thermoelectric chain. For example, elements  206  and  208  are connected by electrical conductor  210  which extends inside the conduit  205 , elements  222  and  220  are connected by electrical conductor  221 , and elements  230  and  232  are connected by electrical conductor  231 . 
     In a similar manner, elements  208  and  220  are connected by electrical conductors  214 ,  216  and  218 , which extend outside the conduit, and elements  222  and  230  are connected by electrical conductors  224 ,  226  and  228 . Conductors  234 ,  236 ,  238  and  240  make similar connections, as do conductors  242 ,  244 ,  248  and  250 . The electrical connections connect the thermoelectric elements into an array in a manner similar to that of conventional thermoelectric modules. The series chain of thermoelectric elements are connected by conductors  247  and  203  to an electrical power source so that current flows in the direction of arrows  209  in order to power the thermoelectric module in a conventional manner. 
     The vertical conductors  214 ,  218 ,  224 ,  228 , etc. are arranged to form the “fins” of a heat sink outside of conduit  205  over which a second fluid can flow outside the conduit in the direction of arrow  260 . The heat sink fins transfer heat to the second fluid. 
     In accordance with the principles of the invention, the electrical conductors that connect either the hot or cold sides of the thermoelectric elements, pass directly through the conduit  205  and are in direct thermal contact with the material to be heated or cooled. For example, conductors  210  and  221  pass through conduit  205  and thus directly contact the material in the conduit  205 . The conductors are fabricated from a material that is both a good electrical and a good thermal conductor, such as copper, aluminum, or other metal. Therefore, heat in the material in conduit  205  will be conducted through the conductor directly to a thermoelectric element without passing through a substrate. 
     In a similar manner, the thermoelectric elements are in-direct thermal contact with the conductors  214 ,  218 ,  224  and  228  that form the fins of a heat sink. The alumina substrates present in the prior art thermoelectric modules are thereby eliminated, resulting in increased heat transfer and thermal efficiency. 
     In order to further increase thermal efficiency, although conductors  210 ,  221 , etc. are shown as thin plates within the conduit  205 , one or more of the conductors  210 ,  221 , etc. can be configured into an effective heat transfer shape such as a fin or vane to further increase the heat transfer efficiency. 
     In another variation, a protective layer  207  can be applied to conductors  210 ,  221 , etc. which lie inside the conduit  205  in order to protect the conductors from a chemical interaction between the conductors and the material in the conduit. Such a coating is shown in FIG. 2A on one side of conductor  210  as an example. Those skilled in the art will understand that such a coating material, if used, would cover all exposed surfaces of the conductors in conduit  205 . A similar material may also be applied to the conductors outside of the conduit  205 . This is particularly important in order to prevent corrosion or short-circuiting of the device in applications where an electrolytic or ionic material is passed by the conductors. This protective layer may be produced by passivating the conductors or by applying some other protective material to the conductors. In either case the protective coating should be made out of thermally conductive material or should be thin so as not to impede heat flow between the conductors and the material. 
     Shown in FIG. 3 is a perspective view of a system making use of a multiple layer thermoelectric arrangement. The thermoelectric unit  300  has conduits through which air or some other fluid passes in perpendicular directions. Upper and lower thermoelectric systems  302 ,  304  are each essentially identical to the unit shown in FIGS. 2A-2C, and each has a current flowing through alternating P-type and N-type thermoelectric elements. For example, the thermoelectric elements of system  302  are part of two separate layers, in between which a conduit  303  is formed through which fluid flows past conductors  310 ,  321 , etc. With the electrical current traveling in a first direction, the material in the conduit  303  is exposed to the cold side of each thermoelectric element and, by the time it reaches the rear side of the unit  300 , it has been reduced in temperature. Thermoelectric system  304  operates in a manner identical to that of system  302 , and will not be described in detail herein. 
     As shown in FIG. 3, the conductive portions of the system  302  that are located to the sides of the thermoelectric elements away from the conduit  303 , extend into perpendicular flow paths  312  and  314 . Likewise, the conductive portions of system  304  located to the sides of the thermoelectric elements away from conduit  305  extend into perpendicular flow paths  314  and  316 . Each surface within which thermoelectric elements are embedded, or to which thermoelectric elements are attached, serves to separate each conduit from adjacent conduits, thereby preventing mixing of the flowing materials. Because the electrical conductors extending into the conduits  312 ,  314  and  316  are each attached to the hot side of their respective thermoelectric elements, the air that flows through conduits  312 ,  314  and  316  of the thermoelectric unit is heated by the conductive portions therein. Similarly, fluid flowing through conduits  303  and  305  is cooled by the conductors therein, each of which is in thermal contact with the cold side of a thermoelectric element. 
     The embodiment of FIG. 3 provides an example of a system that may provide desired heating and/or cooling to a fluid or fluids. Those skilled in the art will recognize that this system may as easily be used as an electrical generator by providing fluid flowing through conduits  303  and  305  that is at a distinctly different temperature than fluid flowing through conduits  312 ,  314  and  316 . Such fluid flow will produce a thermal gradient on the thermoelectric elements of each system, resulting in the development of a DC electrical current in a direction dependent on which of the hotter and cooler fluids flow through which conduits. It will also be recognized that any number of desired thermoelectric systems like that of system  302  and system  304  may be organized in a unit such as that shown in FIG. 3, with interleaved conduits like conduits  312 ,  314  and  316  separating the systems. These systems may also be arranged such that the electrical current flow continues from one system to the next, making for a single electrical circuit. Moreover, the compact shape of the unit may allow it to be used in a number of different capacities. For example, a unit such as that shown in FIG. 3 might be implemented to provide supplemental electrical energy in an automobile by routing hot exhaust gases through conduits in one direction, and cool fresh air through the conduits in the perpendicular direction. Naturally, many other similar uses for such a system exist. 
     A perspective view of an alternative embodiment of the invention is illustrated in FIG.  4 . In this embodiment, a conduit, which carries the material that is cooled or heated, is formed from the conductors that are part of the thermoelectric module. In particular, the difference between the embodiment shown in FIG.  4  and the aforementioned embodiments is that, in those other embodiments, the electrical conductors that comprise the electrical junctions of one side of the thermoelectric module pass through a material-carrying conduit, whereas in FIG. 4, the electrical in connectors themselves form the walls of the conduit. In particular, FIG. 4 shows a section of an electrically conducting conduit  400  that is formed of sections  402  and  404 . The conduit sections are separated by an electrically insulating coupling  406 . Thermoelectric elements are attached on any or all sides of the conduit in a manner such that the conduit walls themselves constitute the electrical connections between the pairs of elements. For examples, the walls of conduit  402  electrically connect elements  412  and  414  and elements  410  and  418 . The elements are further connected together by external electrical connectors such as connectors  424 ,  426 ,  428  and  430 . In this manner, the electrical connections, which constitute either the cold or, the hot side of the thermoelectric module constitute the conduit sections themselves. When the conductors  424  and  428  and others (not shown) are connected to an appropriate electrical energy source, current flows in the directions of arrows  434 ,  436 ,  438  and  440  to cause the conduit walls to heat or cool depending on the direction of current flow. Materials move through the conduit as indicated by arrow  432  and are cooled or heated by direct thermal contact with the walls of the conduit. 
     As with the previous embodiment, a protective layer  442  can be applied to the inner conduit walls in order to protect the conduit from a chemical interaction between the conduit and the material in the conduit. Only a small section of such a coating  442  is shown in the figure. This protective layer can be formed by passivation or other suitable coating techniques. 
     Although exemplary embodiments of the invention have been disclosed, it will be apparent to those skilled in the art that various changes and modifications can be made which will achieve some of the advantages of the invention without departing from the spirit and scope of the invention. For example, it will be obvious to those reasonably skilled in the art that, although the description was directed to conduits with particular shapes and cross-sections, that other designs could be used in the same manner as that described. Other aspects, such as the specific connections between thermoelectric elements and the configuration of the elements, as well as other modifications to the inventive concept are intended to be covered by the appended claims.