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To achieve high thermal-to-electric energy conversion efficiency, it is desirable to operate thermoelectric generator devices over large temperature gradients and also to maximize the thermoelectric performance of the materials used to build the devices. However, no single thermoelectric material is suitable for use over a very wide range of temperatures (~300-1000K). It is therefore necessary to use different materials in each temperature range where they possess optimum performance. This can be achieved in two ways: 1) multistage thermoelectric generators where each stage operates over a fixed temperature difference and is electrically insulated but thermally in contact with the other stages 2) segmented generators where the p- and n-legs are formed of different segments joined in series. The concept of integrating new thermoelectric materials developed at the Jet Propulsion Laboratory into a segmented thermoelectric unicouple has been introduced in earlier publications.

Advanced thermoelectric microdevices integrated into thermal management packages and low power, electrical power source systems are of interest for a variety of space and terrestrial applications. By making use of macroscopic film technology, microgenerators operating across relatively small temperature differences can be conceptualized for a variety of high heat flux or low heat flux heat source configurations. The miniaturization of state-of-the-art thermoelectric module technology based on Bi2Te3 alloys is limited due to mechanical and manufacturing constraints for thermoelement dimensions (100-200μm thick minimum) and number (100-200 legs maximum). We are developing novel thermoelectric microdevices combining high thermal conductivity substrate materials such as diamond or even silicon, thin film metallization and patterning technology, and electrochemical deposition of 10-50μm thick thermoelectric films.