Integrated Thermoelectric Honeycomb Core and Method

A thermoelectric composite sandwich structure for use in aircraft and spacecraft comprising:

• two prepreg composite face sheets;
• an integrated honeycomb core assembled between the face sheets, the honeycomb core comprising:
• a plurality of core elements selected from the group comprising corrugated core sheets and flat core sheets, the core elements coupled together with a core adhesive;
• each core element having a first side substantially coated with a nickel layer having a plurality of first spaced gaps first spaced gaps of a size in the range of from about 0.01 inch to about 0.15 inch and spaced at intervals from each other in a range of about 0.15 inch to about 0.55 inch;
• each core element having a second side substantially coated with an antimony layer having a plurality of second spaced gaps of a size in the range of from about 0.01 inch to about 0.15 inch and spaced at intervals from each other in a range of about 0.15 inch to about 0.55 inch;
• and,
• a plurality of electrical connections for connecting in series the nickel layer to the antimony layer;
• wherein a temperature gradient across the honeycomb core generates power.

A method for making an integrated thermoelectric honeycomb core, comprising:

• providing a corrugated core sheet;
• depositing a negative Seebeck coefficient conductive material with a plurality of first spaced gaps on a first side of the corrugated core sheet;
• depositing a positive Seebeck coefficient conductive material with a plurality of second spaced gaps on a second side of the corrugated core sheet;
• applying a core adhesive at intervals across a plurality of deposited corrugated core sheets;
• assembling and bonding the plurality of deposited corrugated core sheets to create an integrated thermoelectric honeycomb core;
• and,
• electrically connecting deposited negative Seebeck coefficient conductive material to deposited positive Seebeck coefficient conductive material in an alternating pattern along a length of the integrated thermoelectric honeycomb core.

A method for making an integrated thermoelectric honeycomb core comprising:

• providing a flat core sheet;
• depositing a negative Seebeck coefficient conductive material with a plurality of first spaced gaps on a first side of the flat core sheet;
• depositing a positive Seebeck coefficient conductive material with a plurality of second spaced gaps on a second side of the flat core sheet;
• applying a core adhesive at intervals across a plurality of deposited flat core sheets;
• assembling and bonding the plurality of deposited flat core sheets;
• expanding the plurality of deposited flat core sheets to create an integrated thermoelectric honeycomb core;
• and,
• electrically connecting deposited negative Seebeck coefficient conductive material to deposited positive Seebeck coefficient conductive material in an alternating pattern along a length of the integrated thermoelectric honeycomb core.