Thermoelectric module, method of forming a thermoelectric element, and method of thermoelectric module

A method of forming a thermoelectric module, the method comprising:

• placing a mold that has a plurality of holes at a position adjacent to a cooler;
• introducing first and second types of molten thermoelectric-material in the plurality of holes of the mold adjacent to the cooler, so that a first one of the plurality of holes is filled with the first type of molten thermoelectric-material and a second one adjacent to the first one of the plurality of holes is filled with the second type of molten thermoelectric-material;
• solidifying the first and second types of molten thermoelectric-material in the plurality of holes, thereby forming first type and second type thermoelectric elements in the plurality of holes;
• placing the mold having the first type and second type thermoelectric elements on a first substrate that has a plurality of first electrodes so that two adjacent first type and second type thermoelectric elements of the first type and second type thermoelectric elements are in contact with one of the plurality of first electrodes;
• and
• placing a second substrate that has a plurality of second electrodes on the first type and second type thermoelectric elements placed on the first substrate so that the two adjacent first type and second type thermoelectric elements are in contact with two adjacent second electrodes of the plurality of second electrodes.

A method of forming a thermoelectric module, the method comprising:

• placing a first mold that has a first plurality of holes at a position adjacent to a cooler;
• introducing a first type of molten thermoelectric-material in the first plurality of holes of the mold adjacent to the cooler, so that the first plurality of holes is filled with the first type of molten thermoelectric-material;
• solidifying the first type of molten thermoelectric-material in the first plurality of holes, thereby forming first type thermoelectric elements in the first plurality of holes;
• placing a second mold that has a second plurality of holes at the position adjacent to the cooler;
• introducing a second type of molten thermoelectric-material in the second plurality of holes, so that the second plurality of holes is filled with the second type of molten thermoelectric-material;
• solidifying the second type of molten thermoelectric-material in the second plurality of holes, thereby forming second type thermoelectric elements in the second plurality of holes;
• placing the first type and second type thermoelectric elements on a first substrate that has a plurality of first electrodes so that two adjacent first type and second type thermoelectric elements of the first type and second type thermoelectric elements are in contact with one of the plurality of first electrodes;
• and
• placing a second substrate that has a plurality of second electrodes on the first type and second type thermoelectric elements placed on the first substrate so that the two adjacent first type and second type thermoelectric elements are in contact with two adjacent second electrodes of the plurality of second electrodes.

A thermoelectric module comprising:

• a first substrate having a plurality of first electrodes;
• a second substrate having a plurality of second electrodes;
• and
• an array of first type and second type thermoelectric elements disposed between the first and second substrates, the first type and second type thermoelectric elements being connected between the plurality of first electrodes and the plurality of second electrodes,
• wherein two adjacent first type and second type thermoelectric elements of the first type and second type thermoelectric elements are in contact with one of the plurality of first electrodes, and
• the two adjacent first type and second type thermoelectric elements are in contact with two adjacent second electrodes of the plurality of second electrodes.