Thermoelectric evaluation and manufacturing methods

Abstract

A means for determining the electrical resistance and resistivity of thermoelectric material allows quality control at all steps in the construction of a bismuth telluride and antimony telluride thermoelectric generator. The method involves measuring negative thermoelectric voltage with no current flowing and then a measure of negative thermoelectric voltage while forcing known current through the material in the same direction as shorted to accurately determine thermoelectric resistance. A manual and automatic method of manufacturing thermoelectric rings using forcing current for in-process testing means.

1 - 43 . (canceled) 
     
     
         44 . An automated method for assembling and testing a ring of coupons adapted for inclusion in a thermoelectric generator, the method comprising steps of:
 A. robotically assembling an un-bonded coupon that includes at least:
 i. a pair of wafers; 
 ii. a hot fin that is juxtaposed on one side thereof with one of the wafers; and 
 iii. a cold fin that is juxtaposed on one side thereof with the wafer that is juxtaposed with the hot fin; 
   B. using a computer, testing electrical resistance of said un-bonded coupon by:
 i. robotically attaching a volt meter to said un-bonded coupon via a probe; 
 ii. robotically connecting an amp meter in series with said un-bonded coupon; 
 iii. without any external electrical current applied to the un-bonded coupon, using the volt meter to measure a first voltage produced by said un-bonded coupon; 
 iv. while applying a known forced electrical current externally through said un-bonded coupon in a direction current would flow if the un-bonded coupon were short circuited, using the amp meter to measure the forced current, and using the volt meter to measure a second voltage of said un-bonded coupon; and 
 v. calculating electrical resistance for said un-bond coupon using:
 a. the first voltage measured in step B.iii. above while no external current flows through said un-bonded coupon; 
 b. the second voltage measured in step B.iv. while the forced current flows through said un-bonded coupon; and 
 c. the known, externally applied forced current flowing through the un-bonded coupon measured in step B.iv. using the amp meter; 
 
   C. if the electrical resistance calculated for said un-bonded coupon is less than a pre-established coupon resistance threshold, transferring the un-bonded coupon to a furnace for bonding;   D. repeating steps A. through C. until a number of un-bonded coupons required for assembling said ring have been bonded;   E. robotically assembling the bonded coupons into said ring of coupons;   F. using a computer, testing electrical resistance of said un-bonded ring of bonded coupons by:
 i. robotically attaching a volt meter output terminals of said un-bonded ring of bonded coupons; 
 ii. robotically connecting an amp meter in series with output terminals of said un-bonded ring of bonded coupons; 
 iii. without any external electrical current applied to the un-bonded ring of bonded coupons, using the volt meter to measure a first voltage produced by said un-bonded ring of bonded coupons; 
 iv. while applying a known forced electrical current externally through said un-bonded ring of bonded coupons in a direction current would flow if the un-bonded ring of bonded coupons were short circuited, using the amp meter to measure the forced current, and using the volt meter to measure a second voltage of said un-bonded ram of bonded coupons; and 
 v. calculating electrical resistance for said un-bonded ring of bonded coupons using:
 a. the first voltage measured in step F.iii. above while no external current flows through said un-bonded ring of bonded coupons; 
 b. the second voltage measured in step F.iv. while the forced current flows through said un-bonded ring of bonded coupons; and 
 c. the known, externally applied forced current flowing through the un-bonded ring of bonded coupons measured in step F.iv. using the amp meter; and 
 
   G. if the electrical resistance of said un-bonded ring of bonded coupons is less than a pre-established ring resistance threshold, transferrin the un-bonded ring of bonded coupons to a furnace for bonding.   
     
     
         45 . The automated method for assembling and testing of  claim 44  comprising an additional step of:
 H. estimating electrical power output producible by said un-bonded coupon using:
 the first voltage measured for said un-bonded coupon in step B.iii.; and 
 the electrical resistance of said un-bonded coupon calculated in step B.v. 
 
 
     
     
         46 . The automated method for assembling and testing of  claim 44  comprising additional steps of while measuring the first voltage in step B.iii. and while measuring the second voltage in step B.iv.:
 H. heating hot fin of the un-bonded coupon; and 
 I. cooling cold fin of the un-bonded coupon. 
 
     
     
         47 . The automated method for assembling and testing of  claim 46  comprising an additional step of:
 J. estimating electrical power output producible by said un-bonded coupon using:
 i. the first voltage measured for said un-bonded coupon in step B.iii.; and 
 ii. the electrical resistance of said un-bonded coupon calculated in step B.V. 
 
 
     
     
         48 . The automated method for assembling and testing of  claim 44  comprising an additional step of:
 H. estimating electrical power output producible by said un-bonded ring of coupons using:
 i. the first voltage measured for said un-bonded ring of coupons in step F.iii.; and 
 ii. the electrical resistance of said un-bonded ring of coupons calculated in step F.v. 
 
 
     
     
         49 . The automated method for assembling and testing of  claim 44  comprising additional steps of while measuring the first voltage in step F.iii. and while measuring the second voltage in step F.iv.:
 H. heating hot fins included in all of the coupons of the un-bonded ring; and 
 I. cooling cold fins included in all of the coupons of the un-bonded ring. 
 
     
     
         50 . The automated method for assembling and testing of  claim 49  comprising an additional step of:
 J. estimating electrical power output producible by said un-bonded ring of coupons using:
 i. the first voltage measured for said un-bonded ring of coupons in step F.iii.; and 
 ii. the electrical resistance of said un-bonded ring of coupons calculated in step F.v. 
 
 
     
     
         51 . The automated method for assembling and testing a ring of coupons adapted for inclusion in a thermoelectric generator of  claim 44  comprising an additional step of:
 H. using a computer, testing electrical resistance of said bonded ring of coupons by:
 i. robotically attaching a volt meter output terminals of said un-bonded ring of bonded coupons; 
 ii. robotically connecting an amp meter in series with output terminals of said un-bonded ring of bonded coupons; 
 iii. without any external electrical current applied to the un-bonded ring of bonded coupons, using the volt meter to measure a first voltage produced by said un-bonded ring of bonded coupons; 
 iv. while applying a known forced electrical current externally through said un-bonded ring of bonded coupons in a direction current would flow if the un-bonded ring of bonded coupons were short circuited, using the amp meter to measure the forced current, and using the volt meter to measure a second voltage of said un-bonded ring of bonded coupons; and 
 v. calculating electrical resistance for said un-bonded ring of bonded coupons using;
 a. the first voltage measured in step H.iii. above while no external current flows through said un-bonded ring of bonded coupons; 
 b. the second voltage measured in step H.iv. while the forced current flows through said un-bonded ring of bonded coupons; and 
 c. the known, externally applied forced current flowing through the un-bonded ring of bonded coupons measured in step H.iv. using the amp meter. 
 
 
 
     
     
         52 . The automated method for assembling and testing of  claim 51  comprising an additional step of:
 I. estimating electrical power output producible by said bonded ring of coupons using:
 i. the first voltage: measured for said bonded ring of coupons in step H.iii.; and 
 ii. the electrical resistance of said bonded ring of coupons calculated in step H.v. 
 
 
     
     
         53 . The automated method for assembling and testing of  claim 51  comprising additional steps of while measuring the first voltage in step H.iii. and while measuring the second voltage in step H.iv.:
 I. heating hot fins included in all of the coupons of the bonded ring; and 
 J. cooling cold fins included in all of the coupons of the bonded ring. 
 
     
     
         54 . The automated method for assembling and testing of  claim 53  comprising an additional step of:
 K. estimating electrical power output producible by said bonded ring of coupons using:
 i. the first voltage measured for said bonded ring of coupons in step H.iii.; and 
 ii. the electrical resistance of said bonded ring of coupons calculated in step H.v.