Patent ID: 7480984

Claim:
A method of applying a physical barrier to suppress thermal decomposition near a surface of a thermoelectric element, comprising the steps of: having the thermoelectric element with a side surface and an exposed end surface; applying a continuous metal foil over the exposed end surface and up a portion of the side surface of the thermoelectric element; physically binding the continuous metal foil to the exposed end surface and portion of the side surface of the thermoelectric element using a binding member, the continuous metal foil forming a physical barrier enclosing the exposed end surface and portion of the side surface; and heating in a predetermined atmosphere the applied and physically bound continuous metal foil and the thermoelectric element to a sufficient temperature in order to promote bonding between the continuous metal foil and the exposed end surface and portion of the side surface of the thermoelectric element, whereby thermal decomposition is suppressed at the surface of the thermoelectric material enclosed by the physical barrier.