Abstract
A thermoelectric module may include a metallic module housing surrounding a module interior and conductor bridges arranged therein. The module housing may include a cold side wall and a warm side wall connected to cold-side conductor bridges and warm-side conductor bridges, respectively, in a thermally conductive, electrically insulating and permanent manner. The module may also include thermoelectric elements extending between the cold-side and warm-side conductor bridges. The cold side wall may be formed from a first metal material having a first heat expansion coefficient, and the warm side wall may be formed from a second metal material having a second heat expansion coefficient distinct from the first heat expansion coefficient. At least one of the first and second metal materials may be an iron material, the wall formed from the iron material having an electrically insulating coating, including one of a glass-ceramic sol-gel, a silicon oxide, and a polysilazen coating.
Claims
1. A thermoelectric module, comprising: a metallic module housing that surrounds a module interior, a plurality of thermoelectric elements arranged in the module interior; and a plurality of conductor bridges arranged in the module interior for electrically interconnecting the thermoelectric elements; wherein the module housing has a cold side wall on a cold side, the cold side wall being connected to a plurality of cold-side conductor bridges in a thermally conductive, electrically insulating and permanent manner; wherein the module housing has a warm side wall on a warm side, the warm side wall being connected to a plurality of warm-side conductor bridges in a heat-conductive, electrically insulating and permanent manner; wherein the thermoelectric elements extend between the cold-side conductor bridges and the warm-side conductor bridges; wherein the cold side wall is formed from a first metal material and the warm side wall is formed from a second metal material; wherein the first metal material has a first heat expansion coefficient and the second metal material has a second heat expansion coefficient; wherein the second heat expansion coefficient is distinct from the first heat expansion coefficient wherein at least one of the first metal material and the second metal material is an iron material, at least one of the cold side wall and the warm side wall formed from the iron material having an electrically insulating coating, including one of a glass-ceramic sol-gel coating, a silicon (di) oxide coating, and a polysilazen coating.
2. The module according to claim 1, wherein: the first metal material is an iron material, and the cold side wall has an electrically insulating coating, including one of a glass-ceramic sol-gel coating, a silicon (di) oxide coating, and a polysilazen coating; and the second metal material is an iron material, and the warm side wall has an electrically insulating coating, including one of a glass-ceramic sol-gel coating, a silicon (di) oxide coating, and a polysilazen coating.
3. The module according to claim 1, wherein: the first metal material is an iron material, and the cold side wall has an electrically insulating coating, including one of a glass-ceramic sol-gel coating, a silicon (di) oxide coating, and a polysilazen coating; and the second metal material is a titanium material, and the warm side wall has an electrically insulating anodised layer.
4. The module according to claim 1, wherein: the first metal material is an aluminium material, and the cold side wall has an electrically insulating anodised layer; and the second metal material is an iron material, and the warm side wall has an electrically insulating coating, including one of a glass-ceramic sol-gel coating, a silicon (di) oxide coating, a polysilazen coating.
5. The module according to claim 1, wherein the second heat expansion coefficient is smaller than the first heat expansion coefficient.
6. The module according to claim 5, wherein the first heat expansion coefficient is at least 25%, greater than the second heat expansion coefficient.
7. The module according to claim 2, wherein: the first metal material is an austenitic iron material; and the second metal material is one of a ferritic iron material, a ferritic steel material and a ferritic stainless steel material.
8. The module according to claim 1, wherein one of the cold side wall and the warm side wall has an electrically insulating anodised layer, and the other of the cold side wall and the warm side wall has the electrically insulating coating, wherein the conductor bridges are thermally sprayed onto one of the electrically insulating anodised layer and the electrically insulating coating.
9. The module according to claim 8, wherein the conductor bridges are sprayed on in multiple layers, a first layer of the multiple layers sprayed onto the one of the electrically insulating anodised layer and the electrically insulating coating consists of one of an aluminium material or of a titanium material, and an iron material, and a second layer of the multiple layers sprayed onto the first layer consists of one of a copper material and a nickel material.
10. The module according to claim 1, wherein the conductor bridges are configured as separate components and are glued onto the electrically insulated coating.
11. The module according to claim 1, wherein: a metal layer is applied onto the electrically insulating coating at least in a region of the conductor bridges; and the conductor bridges are one of galvanised onto the metal layer or configured as a separate component and soldered onto the metal layer.
12. The module according to claim 11, wherein one of: the metal layer is galvanised onto the electrically insulating coating at least in the region of the conductor bridges; the metal layer is printed on and burnt into the electrically insulating coating; or the metal layer is applied to the the electrically insulating coating by one of a CVD method and a PVD method at least in the region of the conductor bridges.
13. The module according to claim 1, the conductor bridges are printed on and burnt into the electrically insulating coating.
14. The module according to claim 1, wherein the cold side wall along an edge region surrounding the module interior between a cold side and a warm side in a circumferential direction is directly soldered to the warm side wall.
15. The module according to claim 1, further comprising a separate connecting frame between the cold side wall and the warm side wall in a region of an edge region surrounding the module interior between a cold side and a warm side in a circumferential direction, the separate connecting frame being soldered to the cold side wall and to the warm side wall.
16. The module according to claim 1, wherein: the cold side wall includes a cold side frame, which, along an edge region surrounding the module interior between a cold side and a warm side in a circumferential direction of the module housing, runs around in a closed manner and is attached to the cold side wall; the warm side wall includes a warm side frame, which, along the edge region, runs around in a closed manner and is attached to the warm side wall; and the cold side frame is soldered to the warm side frame.
17. The module according to claim 16, wherein at least one of: the cold side frame is one of galvanized, printed on and burned, sprayed and glued onto the cold side wall; and the warm side frame is one of galvanized, printed on and burned, sprayed and glued onto the warm side wall.
18. The module according to claim 3, wherein the conductor bridges are thermally sprayed onto one of the respective electrically insulating anodised layer and onto the respective electrically insulating coating.
19. The module according to claim 4, wherein the conductor bridges are thermally sprayed onto one of the respective electrically insulating anodised layer and onto the respective electrically insulating coating.
20. A thermoelectric module, comprising: a metallic module housing that surrounds a module interior; a plurality of thermoelectric elements arranged in the module interior; and a plurality of conductor bridges arranged in the module interior for electrically interconnecting the thermoelectric elements; wherein the module housing has a cold side including a cold side wall connected to a plurality of cold-side conductor bridges in a thermally conductive, electrically insulating and permanent manner; wherein the module housing has a warm side including a warm side wall connected to a plurality of warm-side conductor bridges in a heat-conductive, electrically insulating and permanent manner; wherein the thermoelectric elements extend between the cold-side conductor bridges and the warm-side conductor bridges; wherein the cold side wall is formed from a first metal material and the warm side wall is formed from a second metal material; wherein the first metal material has a first heat expansion coefficient and the second metal material has a second heat expansion coefficient; wherein the second heat expansion coefficient is smaller than the first heat expansion coefficient; wherein the cold side wall, along an edge region surrounding the module interior between the cold side and the warm side in a circumferential direction, is directly soldered to the warm side wall; and wherein at least one of the first metal material and the second metal material is an iron material, at least one of the cold side wall and the warm side wall formed from the iron material having an electrically insulating coating, including one of a glass-ceramic sol-gel coating, a silicon oxide coating, and a polysilazen coating.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] It shows, in each case schematically
[0031] FIG. 1 a highly simplified cross section of a thermoelectric module,
[0032] FIGS. 2 to 7 in each case a cross section of a cold side wall of the thermoelectric module with different embodiments,
[0033] FIGS. 8 to 13 in each case a cross section of a warm side wall of the thermoelectric module with different embodiments,
[0034] FIGS. 14 and 15 in each case an isometric view of a side wall of the thermoelectric module with different embodiments,
[0035] FIGS. 16 to 18 in each case a cross section of the thermoelectric module in an edge region of a module housing with different embodiments.
DETAILED DESCRIPTION
[0036] According to FIG. 1, a thermoelectric module 1 comprises a metallic module housing 2, which surrounds a module interior 3. In the module interior 3, a plurality of thermoelectric elements 4 are arranged, which are semiconductor elements, which are generally alternately P-doped, i.e. positively doped and N-doped, i.e. negatively doped. In the module interior 3, a plurality of electrically conductive conductor bridges 5 is arranged, with the help of which the thermoelectric elements 4 are electrically interconnected. In particular, such conductor bridges 5 connect a P-doped thermoelectric element 4 with an adjacent N-doped thermoelectric element 4. With the help of the conductor bridges 5, multiple thermoelectric elements 4 are connected in series. Likewise, multiple series connections of the thermoelectric elements 4 can be connected in parallel with the help of the conductor bridges 5. In addition, two such conductor bridges 5 can also serve for connecting an electrical contact 6. Such a connection conductor bridge 1 is marked with 5′ in FIG. 1. Each thermoelectric module 1 comprises at least two such thermoelectric contacts 6, namely for a negative pole connection and a positive pole connection. In FIG. 1, only one of the contacts 6 is visible.
[0037] Interconnecting the thermoelectric elements 4 with the help of the conductor bridges 5 is usually carried out in such a manner that on the electrical contacts 6 of the module 1 an electrical voltage is created when between a cold side 7 of the module 1 and a warm side 8 of the module 1 a temperature differential occurs. Thus, the thermoelectric modules 1 utilise the so-called Seebeck effect, which corresponds to an inversion of the Peltier effect.
[0038] On its cold 7, the module housing 2 comprises a cold side wall 9 which is connected to a plurality of cold-side conductor bridges 5 in a heat-conductive, electrically insulating and permanent manner. The thermoelectric elements 4 extend geometrically between the cold-side and warm-side conductor bridges 5. In the example of FIG. 1, a connecting frame 11 is additionally provided between the cold side wall 9 and the warm side wall 10, which surrounds the housing interior 3 between the cold side 7 and the warm side 8 in a circumferential direction 12 indicated in the FIGS. 14 and 15 by a double arrow surrounding the edge region. The connecting frame 11 in the example of FIG. 1 is configured as a separate component with respect to the cold side wall 9 and with respect to the warm side wall 10 and connected permanently to both side walls 9, 10 in a suitable manner, in particular soldered to these.
[0039] In the module 1 introduced here, the cold side wall 9 is produced from a first metal material which has a first heat expansion coefficient. The warm side wall 10, by contrast, is produced from a second metal material that is distinct from the first metal material, which has a second heat expansion coefficient which differs from the first heat expansion coefficient. Accordingly, the first heat expansion coefficient is either greater or smaller than the second heat expansion coefficient. Preferred is an embodiment, in which the first heat expansion coefficient is greater than the second heat expansion coefficient. The greater first heat expansion coefficient is thus assigned to the cold side wall 9 while the smaller second heat expansion coefficient is assigned to the warm side wall 10. For example, the first heat expansion coefficient is at least 25% greater than the second heat expansion coefficient. Preferably, the first heat expansion coefficient is at least 50% greater than the second heat expansion coefficient. Particularly advantageous is an embodiment, in which the first heat expansion coefficient is at least twice as great as the second heat expansion coefficient.
[0040] The first metal material, from which the cold side wall 9 is produced, is preferably an aluminium material, while the second metal material, of which the warm side wall 10 consists, is preferably a titanium material. Accordingly, a cold side wall 9 of aluminium is preferably combined with a warm side wall 10 of titanium in the module housing 2. In another advantageous embodiment, a cold side wall 9 of an austenitic iron material is combined with a warm side wall 10 of a ferritic iron material in the module housing 2. With the aluminium-titanium combination, the first heat expansion coefficient is more than twice as great as the second heat expansion coefficient. In the case of the austenite-ferrite combination, the first heat expansion coefficient is approximately 50% greater than the second heat expansion coefficient.
[0041] It is clear that other material combinations within the module housing 2 are also conceivable for as long as there is an adequate differential between the heat expansion coefficients of the two side walls 9, 10. For example, a cold side wall 9 of aluminium can be combined with a warm side wall 10 of iron. Likewise, a cold side wall 9 of iron can be combined with a warm side wall 10 of titanium.
[0042] As is evident from FIG. 1, the two side walls 9, 10 of the module housing 2 are each provided, at least on a side facing the module interior 3, with a coating 13 or 14, which is arranged between the respective side wall 9, 10 and the associated conductor bridges 5. The coating 13 or 14 is configured so that on the one hand it brings about an electrical insulation and on the other hand ensures a relatively good heat conductivity between the respective side wall 9, 10 and the respective associated conductor bridges 5.
[0043] Provided that for the cold side wall 9 an aluminium material is used as metal material, the coating is preferably an anodised layer 13. When the cold side wall 9, by contrast, is produced from an iron material, in particular from an austenite, the coating is preferably a sol-gel coating 14. When the warm side wall 10 is produced from a titanium material, the anodised layer 13 is again preferred. When by contrast the warm side wall 10 is produced from an iron material, preferably from a ferrite, a sol-gel coating 14 is again preferred. The following description of specific embodiments by way of the FIGS. 2 to 13 uses these preferred embodiments as a base so that whenever the cold side wall 9 is produced from aluminium material, an anodised layer 13 is present. When the cold side wall 9, by contrast, is produced from an iron material, a sol-gel coating 14 is present.
[0044] Then, similar applies also to the warm side wall 10. If the side wall 10 is produced from a titanium material, an anodised layer 13 is present. When the warm side wall 10 by contrast is produced from an iron material, a sol-gel coating 14 is present.
[0045] Initially it is evident from the FIGS. 2 to 13 that it is practical to provide the respective side wall 9, 10 both on its inside 15 facing the module interior 3 and also on its outside 16 facing away from the module interior 3 with such a coating 13 or 14, as a result of which the module housings 2 are electrically insulating in this respect, for example in order to contact them with metallic heat sources.
[0046] In the embodiment shown in FIG. 2, the conductor bridges 5 are thermally sprayed onto the respective coating 13 or 14, i.e. either onto the anodised layer 13 or onto the sol-gel coating 14. Here, a usual thermal spraying method is employed, i.e. for example cold gas spraying or plasma spraying. For this purpose it can be necessary in advance to suitably prepare the respective side wall 9, 10 for example by sandblasting and/or heating. For spraying on the cold-side conductor bridges 5, a metal material is preferred which has a heat expansion coefficient that is similar to that of the cold side wall 9. When the cold side wall 9 is produced for example from an aluminium material, an aluminium material is also used for the cold-side conductor bridges 5.
[0047] In the example of FIG. 2, the conductor bridges 5 are sprayed on in two layers, wherein a first layer 17 is directly sprayed onto the respective coating 13 or 14, while a second layer 13 is subsequently sprayed onto the first layer 17. The first layer 17 is matched to the cold side wall 9 with respect to the heat expansion coefficient while the second layer 18 is selected with respect to as simple as possible a connection with the thermoelectric elements 4. For example, the second layer 18 can be produced from a copper material or from a nickel material, which simplifies the reduction of soldered connections.
[0048] In the embodiment shown in FIG. 3, the conductor bridges 5 are provided in the form of separate components, which are glued onto the respective coating 13 or 14 in a suitable manner. In FIG. 3, a corresponding adhesive layer is marked with 19.
[0049] In the embodiment shown in FIG. 4, a metal layer 20 is initially applied in each case onto the respective coating 13 or 14 at least in the region of the cold-side conductor bridges 5. This metal layer 20 can, in principle, be directly applied onto the respective coating 13 or 14. However in FIG. 4 a preferred embodiment is shown, in which an activation layer 20 or adhesive base layer 21 is applied onto the respective coating 13 or 14 in advance, onto which the respective metal layer 20 is then applied. The conductor bridges 5 can then be galvanised for example onto the metal layer 20. It is likewise possible to solder the conductor bridges 5 in the form of separate components onto the metal layer 20.
[0050] The metal layer 20 in turn can be galvanised onto the respective coating 13 or 14 or onto the respective activation layer 21. It is likewise possible to print on and burn the metal layer 20 into the coating 13 or 14 or the activation layer 21. Here, a simple screen printing method can be employed. Alternatively it is likewise possible to apply the metal layer 20 by means of a CVD method or by means of a PVD method onto the coating 13 or 14 respectively or onto the respective activation layer 21.
[0051] FIG. 5 shows an embodiment, in which the conductor bridges 5 are directly printed onto the respective coating 13 or 14. As printable, pasty conductor bridge material, a mixture of metal particles, glass particles and a suitable binder are employed for example. Following the application of the pasty conductor bridge material, for example by way of the screen printing method, burning-in takes place, during which the glass particles bond with the anodised layer 13 or with the sol-gel coating 14, while the binder mixture evaporates. A porous yet solid metallic conductor bridge structure for example of copper or on a copper basis remains, which via the glass components is permanently connected to the respective coating 13 or 14. At the same time, this metallic conductor bridge structure is suitable in a special way for producing a soldered connection with the thermoelectric elements 4.
[0052] In the embodiment shown in FIG. 6, the conductor bridges 5 provided as separate bodies are permanently connected to the respective coating 13 or 14 via a metallic coating structure 22 or metal layer 22. This coating structure 22 can be applied and burned in on the respective coating 13, 14 in the form of a pasty coating material. For example, this pasty coating material consists of a mixture of metal particles, glass particles and a binder mixture which is printable and can be applied to the respective coating 13, 14 for example by means of silk screen printing. By burning-in, the glass particles of the coating paste bond with the respective coating 13 or 14 while the binding mixture evaporates. The solid metallic coating structure 22 then remains, which can for example comprise copper or a copper alloy as metal component.
[0053] Finally, FIG. 7 shows an embodiment in which a metal coating 23 is likewise directly applied onto the respective coating 13 or 14 by means of CVD method or by means of PVD method. Onto this metal layer 23, the conductor bridges 5 which are configured as separate components can then be applied, for example by means of a soldering method. Alternatively, the conductor bridges 5 can also be galvanised onto this metal layer 23.
[0054] While the FIGS. 2 to 7 present versions for configuring the cold side wall 9 or version for producing the cold side wall 9, the FIGS. 8 to 13 analogously thereto show configurations of the warm side wall 10 or methods that are analogous thereto for producing the warm side wall 10.
[0055] Accordingly, FIG. 8, analogously to FIG. 2, shows an embodiment in which the warm-side conductor bridges 5 are thermally sprayed onto the respective coating 13 or 14. Again shown is a two-layer configuration of the conductor bridges 5. The first layer 17 can be produced, in principle, from an aluminium material, but it is preferably a material which has a heat expansion coefficient that is similar to the warm side wall 10. Accordingly, the use of a titanium material or of a ferritic iron material for the first layer 17 of the warm-side conductor bridges 5 is conceivable for example. The second layer 18 is sprayed onto the first layer 17 and is characterized by a favourable connectability to the thermoelectric elements 4. For example, the second layer 18 is produced from a metal material on copper bases or nickel bases so that it can be easily soldered to the thermoelectric elements 4.
[0056] According to FIG. 9, which is configured analogous to the version of FIG. 3, the warm-side conductor bridges 5 can be glued onto the respective coating 13 or 14 of the warm side wall 10 in the form of separate bodies. A corresponding adhesive layer is likewise marked with 19 in FIG. 9.
[0057] FIG. 10 shows a configuration analogous to FIG. 4, in which a metal layer 20 is applied. This can be applied either directly onto the respective coating 13 or 14. However, an embodiment in which initially a prime layer or activation layer 21 is initially applied directly onto the respective coating 13 or 14 while the aforementioned metal layer 20 is then applied onto this activation layer 21. Here, too, the activation layer 21can be formed for example from palladium, while seeding in acid with ionogenic metalisation and upstream pickling and activation steps can be employed. Following this, an etching step can be required in order to remove excess coating material. The warm-side conductor bridges 5 can then be soldered onto the metal layer 20 for example in the form of separate bodies. For example, a tin-containing solder can be employed here.
[0058] Analogously to FIG. 5, FIG. 11 shows a version in which the warm-side conductor bridges 5 are applied to and burned into the respective coating 13 or 14 in the form of a pasty compound. Here, a pasty conductor bridge material that is printable for example by means of screen printing technology can also be employed. This conductor bridge base can comprise a mixture of metal particles, glass particles and a binder or binder mixture. The glass components create the connection with the coating 13 or 14 while the metal particles make possible good solderability to the thermoelectric elements 4.
[0059] FIG. 12 substantially corresponds to FIG. 6. Accordingly, a metal layer 22 is printed and burned in onto the respective coating 13, 14 of the warm side wall 10. Following this, the conductor bridges 5 provided in the form of separate bodies can be galvanically soldered onto the metal layer 22.
[0060] FIG. 13 now largely corresponds to FIG. 7 and accordingly shows an embodiment in which a metal coating 23 is applied, at least in the region of the warm-side conductor bridges 5, onto the respective coating 13 or 14 of the warm side wall 10 by means of a CVD method or by means of a PVD method. Following this, the conductor bridges 5 can be soldered onto the metal coating 23 in the form of separate bodies. It is likewise conceivable to apply the warm-side conductor bridges 5 onto the respective metal layer 23. Galvanising in this case can be realised with current or without current.
[0061] The FIGS. 14 and 15 each show one of the side walls 9, 10, wherein within the module housing 2 at least one of the side walls 9, 10 is configured according to FIG. 14 or according to FIG. 15. Practical are embodiments in which either both sides walls 9, 10 are configured according to FIG. 14 or according to FIG. 15.
[0062] According to FIG. 14, the respective side wall 9, 10 comprises a stepped edge 24 (for the cold side wall 9) or 25 (for the warm side wall 10). This edge 24 or 25 runs around in the circumferential direction 12 in a closed manner about the housing interior 3, in which the conductor bridges 5 are arranged.
[0063] In the embodiment shown in FIG. 15, the respective side wall 9 or 10 is configured as a flat metal sheet, i.e. as a two-dimensional structure. Noticeable is a circumferential surround 26 which is closed in the circumferential direction 12, which likewise surrounds the module interior in which the conductor bridges 5 are arranged. The conductor bridges 5 are not shown here, while the adhesive layer 19 of the FIGS. 3 and 9, the metal coating of the FIGS. 4 and 10, the metal coating 22 of the FIGS. 6 and 12 and the metal coating 23 of the FIGS. 7 and 13 are visible. Practically, the surround 26 has the same structure as the mentioned layers 19, 20, 22, 23, which are employed with the respective side wall 9 or 10 in order to fix the conductor bridges 5 thereon.
[0064] According to FIG. 16, the cold side wall 9 and the warm side wall 10 can be soldered directly to one another along the previously mentioned steps 24 and 25. The module housing 2 then substantially consists only of the cold side wall 9 and the warm side wall 10.
[0065] In the embodiment shown in FIG. 17, a connecting frame 27 that is separate with respect to the side walls 9, 10 is provided between the cold side wall 9 and the warm side wall 10 in the region of the edge region 30 circulating in the circumferential direction 12, which on the one hand is soldered to the cold side wall 9 and on the other hand to the warm side wall 10. The connecting frame 27 is practically configured completely closed circumferentially in the circumferential direction 12. The electrical contacts 6 are suitably passed through the connecting frame 27. In this case, the module housing 2 substantially consists of the two side walls 9, 10 and the connecting frame 27.
[0066] Finally, FIG. 18 shows an embodiment in which the cold side wall 9 comprises a cold side frame 28 which in the edge region along the circumferential direction runs around in a closed manner and surrounds the housing interior 3. In this case, the warm side wall 10 is also equipped with a warm side frame 29 which runs around along the circumferential direction 12 about the module interior 3 in a closed manner. The cold side frame 28 is practically soldered to the warm side frame 29. In principle, the cold side frame 28 can be soldered to the cold side wall 9. Likewise, the warm side frame 29 can be soldered to the warm side wall 10. However the embodiment indicated in FIG. 15 is preferred, in which the cold side frame 28 like the cold-side conductor bridges 5 is attached to the cold side wall 9. Likewise, the warm side frame 29, like the warm-side conductor bridges 5, can be attached to the warm side wall 10. In particular, the surround 26 indicated in FIG. 15 can also be employed, which can be formed for example by an adhesive layer 19 or by a metal layer 20 or 22 or 23, with the help of which the respective conductor bridges 5 can also be fastened to the respective side wall 9 or 10. In these cases, the respective coating 13 or 14 is then realised as far as to the edge of the respective side wall 9, 10 which simplifies the production. Provided that the respective frame 28, 29 just as the connecting frame 27 is soldered to the associated side wall 9, 10, the respective coating 13, 14 then extends at least on the respective inside 15 practically not as far as to the edge of the respective side wall 9, 10 but the edge region 30 in particular remains free of the respective coating 13, 14.
