Method for roll-to-roll production of flexible, stretchy objects with integrated thermoelectric modules, electronics and heat dissipation
AssigneePalo Alto Research Center Incorporated
InventorsJohn Steven Paschkewitz, Corie Lynn Cobb, David Mathew Johnson, Gabriel Iftime, Victor Alfred Beck, Tse Nga Ng, Ranjeet Rao
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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.
Claims14
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.
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.
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.
Dependencies are inferred from the claim text.