Title: Method of fabricating thermoelectric power generator modules

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Claims: What is claimed is:

1. A method of fabricating thermoelectric power generator modules, each having an array of semiconductor elements tightly supported in a thin supporting matrix plate formed of electrically and thermally insulating material, the method comprising:

a. providing said electrically and thermally insulating material of said plate in solid form;

b. tightly supporting an array of longitudinally elongated n- and p-type semiconductor elements in a thick solid supporting matrix of said electrically and thermally insulating material of said plates;

c. slicing said thick supporting matrix in a direction transverse to the longitudinal axis of the semiconductor elements to form a plurality of thin matrix plates, said matrix plates each supporting an array of n- and p-type semiconductor elements; and,

d. applying a pattern of electrically conductive pads on opposite surfaces of said matrix plates to electrically connect n- and p-type semiconductor elements in series to form a thermoelectric power generator.

2. The method of claim 1 wherein said array of semiconductor elements comprises a three dimensional array formed from alternating n- and p-type semiconductor elements in substantially parallel relationship.

3. A method of claim 2 wherein said supporting matrix comprises a block of solid material having a series of channels extending therethrough.

4. A method of claim 3 wherein said channels are circular in cross-section.

5. A method of claim 2 wherein said supporting matrix comprises a series of stacked sheets, each sheet having therein supporting channels for said semiconductor elements.

6. A method of claim 1 wherein the application of a pattern of electrically conductive pads is done by depositing a uniform conductive layer on opposite surfaces of said matrix slabs, applying a masking grid thereover, electroplating a metallic layer over areas not covered by said grid, and etching said uniform conductive layers at areas not covered by the electroplated metal.

7. A method of claim 6 wherein conductive pads are simultaneously applied to at least one side of said matrix slabs, said conductive pads being suitable for conductive terminals to and from said plate.

8. A method of claim 1 including the additional steps of coating one surface of the thermoelectric power generator with an electrically insulating coating having high solar radiation absorptivity and low infrared emissivity and coating the other surface with an electrically insulating material having high infrared radiation emissivity to thereby form a solar thermoelectric power generator.

9. A modular unit for converting solar energy into electrical power and heat, comprising, in combination:

a. a frame;

b. a thermoelectric plate contained within said frame, said thermoelectric plate being coated on a first side with an electrically insulating material having high solar radiation absorptivity and low infrared emissivity and coated on a second side with an electrically insulating material having high infrared emissivity;

c. means for circulating a cold liquid in thermal contact with the second side of said thermoelectric plate;

d. a bottom cover;

e. a transparent top cover;

f. electrical contacts on the outside of said frame; and,

g. means for electrically connecting the electrical contacts on the outside of said frame to the thermoelectric plate within said frame.

10. A modular unit of claim 9 wherein said means for electrically connecting comprise a pin extending through a wall of said frame and a spring member within said frame, said spring member being in electrical contact with said pin and said thermoelectric plate.

Other info:

Inventors: Niculescu, Vasile (W. Wellington, CT, US)

Application Number: 851929
Filing Date: 1977-11-16
Publication_date: 1979-04-10
Assignee:
Primary Class(es): 136/206 136/203, 136/204, 136/211, 136/212, 438/55
Other Classes:
US Patent Ref:

3252205	May, 1966	Hancock et al.	136/212.
3326726	Jun, 1967	Bassett et al.	136/203.
3509620	May, 1970	Phillips	136/211.
3626583	Dec, 1971	Abbott et al.	136/212.
3775218	Nov, 1973	Hare et al.	136/212.
3781176	Dec, 1973	Penn et al.	136/212.
3887365	Jun, 1975	Sherfey	75/DIG.
3977909	Aug, 1976	Cremonese	136/206.

Other Refs:
Primary Examiner: Sebastian, Leland A.
Assistant Examiner:
Attorney: Brook; David E.