Method for roll-to-roll production of flexible, stretchy objects with integrated thermoelectric modules, electronics and heat dissipation

Patent metadata

Field	Value
Publication number	US-9543495-B2
Application number	US-201414581542-A
Country	US
Kind code	B2
Filing date	Dec 23, 2014
Priority date	Dec 23, 2014
Publication date	Jan 10, 2017
Grant date	Jan 10, 2017

Abstract

A method of forming a flexible thermal regulation device having multiple functional layers. The layers of the device are formed using various manufacturing techniques and are then integrated to form a sheet having multiple devices disposed thereon. The individual devices are then formed from the sheet.

First claim

The invention claimed is:

1. A method of manufacturing an active temperature control device, comprising:
forming thermoelectric elements;
forming a thermal energy transfer layer of interconnected thermoelectric elements integrated in functionally graded material;
forming a thermal exchange layer configured to exchange thermal energy with the thermal energy transfer layer; and
integrating the thermal energy transfer layer and the thermal exchange layer to be in thermal communication with each other.

2. A method of manufacturing the active temperature control device of claim 1 , wherein forming the thermoelectric elements, comprises:
forming an extrusion of a semiconductor material;
applying at least a coating of functionally graded material to the extrusion;
cutting the coated extrusion into cross-sections to form thermoelectric elements, the thermoelectric elements having an exposed cross-section of semiconductor material surrounded by at least a layer of functionally graded material.

3. A method of manufacturing the active temperature control device of claim 1 , wherein forming the thermal energy transfer layer, comprises:
forming a functionally graded sheet having interconnect circuitry disposed thereon;
placing thermoelectric elements on the interconnect circuitry of the functionally graded material;
surrounding the periphery of the thermoelectric elements with functionally graded material;
forming interconnects above the thermoelectric elements; and
applying functionally graded material about the interconnects, the thermoelectric elements electrically connected and integrated into a functionally graded material.

4. A method of manufacturing the active temperature control device of claim 1 , wherein forming the thermal energy transfer layer, comprises:
forming first interconnects spaced apart;
depositing a first layer of functionally graded material in the spaces around the first interconnects;
disposing spaced apart thermoelectric elements on the first interconnects, the thermoelectric elements electrically coupled to the first interconnects;
depositing a second layer of functionally graded material about the periphery of the thermoelectric elements;
disposing second interconnects on the thermoelectric elements, the thermoelectric elements electrically coupled to the second interconnects;
depositing a third layer of functionally graded material about the second interconnects.

5. A method of manufacturing the active temperature control device of claim 4 , wherein the first interconnects are formed on functionally graded substrate.

6. A method of manufacturing the active temperature control device of claim 1 , wherein forming the thermal exchange layer comprises forming a layer of functionally graded, thermally conductive material.

7. A method of manufacturing the active temperature control device of claim 1 , wherein forming the thermal exchange layer, comprises:
forming a base;
forming a flexible heat pipe disposed on the base; and
forming a textured thermally conductive polymer layer in thermal communication with the heat pipe.

8. A method of manufacturing the active temperature control device of claim 1 , wherein the thermal exchange layer is a thermally conductive polymer having a first textured surface.

9. A method of manufacturing the active temperature control device of claim 8 , wherein the texturing of the thermally conductive polymer is formed using an electrohydrodynamic film patterning process.

10. A method of manufacturing the active temperature control device of claim 1 , wherein integrating the thermal energy transfer layer and the thermal exchange layer, comprises thermally bonding the layers.

11. A method of manufacturing the active temperature control device of claim 1 , further comprising:
forming an adhesive layer; and
integrating the adhesive layer, the thermal energy transfer layer and the thermal exchange layer to be in thermal communication with each other.

12. A method of manufacturing the active temperature control device of claim 1 , further comprising:
forming a protective layer; and
integrating the protective layer, the thermal energy transfer layer and the thermal exchange layer.

13. A method of manufacturing an active temperature control device, comprising:
forming an extrusion of thermoelectric material;
applying at least a layer of functionally graded material to the extrusion of thermoelectric material;
cross-sectioning the layered extrusion to form thermoelectric elements;
arranging the thermoelectric elements in a layout pattern;
depositing material about the periphery of the thermoelectric elements to form a thermoelectric layer;
forming a flexible interconnect layer;
disposing compliant structures on the interconnect layer in the layout pattern;
forming first interconnects on the flexible interconnect layer;
placing the thermoelectric layer on the interconnect layer, the thermoelectric elements disposed atop the compliant structures and electrically coupled to the first interconnects;
disposing second interconnects on the thermoelectric elements, the second interconnects electrically coupling the thermoelectric elements;
depositing functionally graded material about the second interconnects;
forming a thermal energy transfer layer having electrically interconnected thermoelectric elements disposed in a functionally graded material and disposed atop a flexible interconnect layer having compliant structures arranged with the thermoelectric elements;
forming a thermal spreading layer having at least a thermally conductive feature disposed in a functionally graded material;
forming a thermally conductive polymer;
texturing the thermally conductive polymer;
integrating the textured thermally conductive polymer and thermal spreading layer to form a thermal energy exchange layer; and
integrating the thermal energy exchange layer and the thermal energy transfer layer.

14. A method of manufacturing an active temperature control device, comprising:
forming a user interface layer;
forming a thermal energy transfer layer having thermoelectric elements disposed thereon in a functionally graded material
forming a thermal spreading layer;
forming a thermal exchange layer;
forming a protective layer; and
integrating the user interface layer, the thermal energy layer, the thermal spreading layer, the thermal exchange layer and the protective layer.

Assignees

• Palo Alto Res Ct Inc

Inventors

• Paschkewitz John Steven
• Cobb Corie Lynn
• Johnson David Mathew
• Iftime Gabriel
• Beck Victor Alfred
• Ng Tse Nga
• Rao Ranjeet

Classifications

• H01L35/34 Primary

  Electricity · mapped topic

• H01L35/32

  Electricity · mapped topic

• H01L35/10

  Electricity · mapped topic

• H01L35/30

  Electricity · mapped topic

• H10N10/17

  characterised by the structure or configuration of the cell or thermocouple forming the device · CPC title