Mass production method for new structure thermoelectric elements

Abstract

The present invention provides a mass production method for novel thermoelectric elements, comprising: (a) filling a spacer portion located inside a mold portion with thermoelectric material powder so as to surround the inside and outside of the spacer portion; (b) applying pressure to the spacer portion with a punch; (c) sintering the thermoelectric material powder using spark plasma to produce a sintered body; and (d) cutting the sintered body into a predetermined size to produce a large number of thermoelectric elements.

Description

[Technical Field]

[0001] The present invention relates to a mass production method for thermoelectric elements with a new structure, and more particularly to a mass production method for thermoelectric elements with a new structure, in which thermoelectric material powder and spacer parts are mixed together to reduce production costs while mass producing thermoelectric elements. [Background technology]

[0002] Thermoelectric devices are a type of energy harvesting device. They typically include a heat source, a heat sink, and a thermopile. A thermopile is made up of multiple thermocouples connected in series and is used to convert a portion of the thermal energy into energy.

[0003] Thermoelectric devices are typically constructed using semiconductor materials that are electrically connected in series and thermally connected in parallel to form two junctions, forming a thermocouple. The semiconductor materials are typically N-type and P-type, and in a typical thermoelectric device, an electrically conductive junction is formed between the P-type and N-type semiconductor materials, and carriers move from the hot junction to the cold junction as a result of thermal diffusion, inducing an electric current.

[0004] 1(a) and 1(b) are perspective views in one direction showing a configuration for producing a sintered body according to the prior art and the sintered body.

[0005] According to the conventional technology shown in FIGS. 1(a) and 1(b), a sintered body is manufactured using an SPS apparatus, and then cut into a predetermined size to manufacture a thermoelectric element.

[0006] Specifically, referring to FIG. 1(a), the mold unit 10 included in the SPS apparatus includes a mold 11, a punch 12 including a first punch 12a and a second punch 12b disposed above and below the mold 11, a sheet 13 including a first sheet 13a disposed below the first punch 12a and a second sheet 13b disposed above the second punch 12b, and a spacer 14 disposed between the first and second sheets 13a and 13b.

[0007] Referring to FIG. 1(b), the diameter (a) of the sintered body manufactured by the above-mentioned conventional technology is 12 cm to 15 cm, the height (b) of the sintered body is 2 cm to 3 cm, and the weight of the sintered body is 2 kg to 2.5 kg.

[0008] However, the above-mentioned conventional technology has a disadvantage in terms of cost since the sintered body is made entirely of thermoelectric material, and also has a problem in that the outer part must be discarded during cutting since the sintered body is formed in a circular shape. [Prior art documents] [Patent documents]

[0009] [Patent Document 1] Korean Patent Registration No. 10-1152222 (May 25, 2012) Summary of the Invention [Problem to be solved by the invention]

[0010] In order to solve the above problems, an object of the present invention is to provide a method for mass-producing thermoelectric elements with a new structure, in which a thermoelectric material powder and a spacer are mixed, sintered using an SPS apparatus to produce a sintered body, and then the sintered body is cut to mass-produce thermoelectric elements in a single process.

[0011] The technical problems that the present invention aims to solve are not limited to the technical problems mentioned above, and other technical problems not mentioned will be clearly understood by those skilled in the art to which the present invention pertains from the following description. [Means for solving the problem]

[0012] To achieve the above object, the present invention provides a method for mass-producing thermoelectric elements with a novel structure, comprising: (a) filling a spacer portion positioned inside a mold portion with thermoelectric material powder so as to surround the inside and outside of the spacer portion; (b) applying pressure to the spacer portion with a punch portion; (c) sintering the thermoelectric material powder using spark plasma to produce a sintered body; and (d) cutting the sintered body to a predetermined size to produce a large number of thermoelectric elements.

[0013] In order to achieve the above object, the present invention provides a method for mass-producing novel thermoelectric elements, comprising: (a) filling a plurality of spacer portions positioned inside a mold portion with thermoelectric material powder so as to surround the inside and outside of the spacer portions; (b) using a punch portion to pressurize the plurality of spacer portions; (c) using a spark plasma sintering device to sinter the thermoelectric material powder using spark plasma to produce a plurality of sintered bodies; and (d) cutting the plurality of sintered bodies into a predetermined size to produce a plurality of thermoelectric elements.

[0014] In an embodiment of the present invention, the step (a) can include: (a1) inserting an upper portion of a lower punch provided in the punch unit into the interior of the mold unit; (a2) supplying the thermoelectric material powder onto an upper surface of the lower punch; (a3) ​​arranging the spacer unit on top of the thermoelectric material powder supplied onto the upper surface of the lower punch; (a4) supplying the thermoelectric element powder into the interior of the mold unit; and (a5) inserting a lower portion of an upper punch provided in the punch unit into the interior of the mold unit.

[0015] In an embodiment of the present invention, the step (a) may include: (a1) inserting an upper portion of a lower punch provided in the punch unit into the interior of the mold unit; (a2) arranging one of the plurality of sheet units on the upper portion of the lower punch; (a3) ​​supplying the thermoelectric material powder on an upper surface of the one of the sheet units; (a4) arranging the spacer unit on the upper portion of the thermoelectric material powder supplied on the upper surface of the one of the sheet units; (a5) supplying the thermoelectric element powder into the interior of the mold unit; (a6) arranging another of the plurality of sheet units on the upper portion of the spacer unit; and (a7) inserting a lower portion of an upper punch provided in the punch unit into the interior of the mold unit.

[0016] In an embodiment of the present invention, in step (a4), the spacer portion has a rectangular parallelepiped shape extending elongated in one direction, and in step (a4), the thermoelectric element powder is supplied into the mold portion to surround the spacer portion.

[0017] In an embodiment of the present invention, in step (a4), the spacer portion includes a number of horizontal spacers extending horizontally and spaced apart from each other in the vertical direction; and a pair of vertical spacers extending vertically and formed at both ends of the number of horizontal spacers; and in step (a5), the thermoelectric material powder is supplied into the mold portion to fill a number of slits formed between the number of horizontal spacers and the pair of vertical spacers, thereby surrounding the spacer portion.

[0018] In an embodiment of the present invention, the step (a) can include the steps of: (a1) arranging a lowest spacer portion of the plurality of spacer portions on an upper portion of a lower punch provided in the punch unit, and then supplying the thermoelectric material powder inside the lowest spacer portion; (a2) arranging an n-layer spacer portion of the plurality of spacer portions on an upper portion of the lowest spacer portion, and then supplying the thermoelectric material powder inside the n-layer spacer portion; and (a3) ​​arranging an uppermost spacer portion of the plurality of spacer portions on an upper portion of the n-layer spacer portion, and then supplying the thermoelectric material powder inside the uppermost spacer portion.

[0019] In an embodiment of the present invention, the step (a1) can include the steps of: (a11) disposing a lowest sheet portion of the plurality of sheet portions on top of the lower punch; (a12) supplying the thermoelectric material powder on top of the lowest sheet portion; (a13) disposing the lowest spacer portion on top of the thermoelectric material powder supplied on the top of the lowest sheet portion; (a14) supplying the thermoelectric material powder on top of the lowest spacer portion; (a15) disposing any one of the plurality of sheet portions on top of the thermoelectric material powder supplied on top of the lowest spacer portion; and (a16) disposing an n-layer support portion of the plurality of support portions on top of any one of the sheet portions.

[0020] In an embodiment of the present invention, the step (a2) may include: (a21) arranging an n-layer sheet portion of the plurality of sheet portions on top of the n-layer support portion; (a22) supplying the thermoelectric material powder on top of the n-layer sheet portion; (a23) arranging an n-layer spacer portion of the plurality of spacer portions on top of the thermoelectric element powder supplied on top of the n-layer sheet portion; and (a24) supplying the thermoelectric material powder on top of the n-layer spacer portion; and the steps (a21) to (a24) may be repeated a predetermined number of times until n (where n=a natural number) is reached.

[0021] In an embodiment of the present invention, the step (a3) ​​can include: (a31) a step of disposing another one of the plurality of sheet portions on top of the thermoelectric material powder supplied on top of the n-layer spacer portion; (a32) a step of supplying the thermoelectric material powder on top of the other one of the sheet portions; (a33) a step of disposing an uppermost spacer portion of the plurality of spacer portions on top of the thermoelectric material powder supplied on top of the other one of the sheet portions; (a34) a step of supplying the thermoelectric material powder on top of the uppermost spacer portion; (a35) a step of disposing an uppermost sheet portion of the plurality of sheet portions on top of the thermoelectric material powder supplied on top of the uppermost spacer portion; and (a35) a step of disposing an upper punch provided in the punch unit on top of the uppermost sheet portion.

[0022] In an embodiment of the present invention, the method may further include, between steps (c) and (d), a step of removing the plurality of sintered bodies sintered inside the mold part after an upper punch and a lower punch provided in the punch part are moved up and down and separated from the mold part.

[0023] In an embodiment of the present invention, the method may further include, between steps (c) and (d), a step of removing the sintered body sintered inside the mold part after the upper punch and the lower punch are moved up and down and separated from the mold part.

[0024] In an embodiment of the present invention, the step (d) may include: (d1) cutting both sides of the plurality of sintered bodies in the vertical direction; (d2) cutting the plurality of sintered bodies in the horizontal direction while maintaining a predetermined interval in the vertical direction; (d3) cutting the plurality of sintered bodies in the vertical direction while maintaining a predetermined interval in the horizontal direction; and (d4) manufacturing the plurality of thermoelectric elements.

[0025] In an embodiment of the present invention, the step (d) may include: (d1) cutting the sintered body vertically while maintaining a predetermined interval in the horizontal direction; and (d2) manufacturing the plurality of thermoelectric elements.

[0026] In an embodiment of the present invention, the step (d) may include: (d1) cutting both sides of the sintered body in the vertical direction; (d2) cutting the sintered body in the horizontal direction while maintaining a predetermined interval in the vertical direction; (d3) cutting the sintered body in the vertical direction while maintaining a predetermined interval in the horizontal direction; and (d4) manufacturing the plurality of thermoelectric elements.

[0027] In order to achieve the above-mentioned object, the present invention provides a new structure thermoelectric element manufactured by the mass production method of a new structure thermoelectric element as described above, which includes a hexahedral spacer; and a thermoelectric material surrounding four of the six sides of the spacer except for two opposing sides, and the two opposing sides of the spacer are exposed to the outside. [Effects of the Invention]

[0028] The advantages of the present invention as configured above are that thermoelectric material powder and a spacer are mixed, and then sintered using an SPS apparatus to produce a sintered body, and the sintered body is then cut to mass-produce thermoelectric elements in a single process, and that the amount of thermoelectric material powder used can be reduced, thereby reducing production costs.

[0029] The effects of the present invention are not limited to the effects described above, but include all effects that can be inferred from the configuration of the invention described in the detailed description of the present invention or the claims. [Brief explanation of the drawings]

[0030] [Figure 1] FIG. 1 is a perspective view in one direction showing a configuration for producing a sintered body according to a conventional technique and the sintered body. [Figure 2] 1 is a flow chart showing a mass production method of the novel structure thermoelectric element according to the first and second embodiments of the present invention. [Figure 3] 1 is a process flowchart conceptually illustrating detailed steps of a mass production method for new structure thermoelectric elements according to a first embodiment of the present invention. [Figure 4] 1 is a process flowchart showing detailed steps of a mass production method for a new structure thermoelectric element according to a first embodiment of the present invention. [Figure 5] 10 is a perspective view in one direction showing a molding device for carrying out a mass production method for new structure thermoelectric elements according to a second embodiment of the present invention. FIG. [Figure 6] 10 is a view showing that a spacer part is fixed to an inner surface of a mold part in a mass production method of a thermoelectric element with a new structure according to second and third embodiments of the present invention. [Figure 7] FIG. 10 is a perspective view in one direction showing a sintered body including a spacer portion and a thermoelectric element portion formed by sintering thermoelectric material powder filled to surround the inside and outside of the spacer portion, in a method for mass-producing new-structure thermoelectric elements according to second and third embodiments of the present invention. [Figure 8]10 is a view illustrating the removal of both sides of a sintered body including a spacer portion and a thermoelectric element portion formed by sintering thermoelectric material powder filled to surround the inside and outside of the spacer portion in a mass production method of a novel structure thermoelectric element according to second and third embodiments of the present invention. [Figure 9] 10 is a diagram illustrating the manufacturing of a large number of thermoelectric elements by cutting a sintered body formed by the method for mass-producing thermoelectric elements with a new structure according to second and third embodiments of the present invention. [Figure 10] 1 is a perspective view in one direction showing a large number of thermoelectric elements manufactured by a mass manufacturing method for new structure thermoelectric elements according to second and third embodiments of the present invention. [Figure 11] 4 is a flowchart showing a mass production method of a new structure thermoelectric element according to a third embodiment of the present invention. [Figure 12] 10 is a perspective view in one direction showing a molding device for carrying out a mass production method for a new structure thermoelectric element according to a third embodiment of the present invention. FIG. [Figure 13] 1 is a graph showing the power generation cost and temperature difference according to the content of thermoelectric material. [Figure 14] 1 is an actual photograph showing a new structure thermoelectric element manufactured by a mass manufacturing method of a new structure thermoelectric element according to first to third embodiments of the present invention. [Figure 15] 1 is a perspective view in one direction showing the sizes of a sintered body manufactured by conventional technology and a sintered body manufactured by the mass manufacturing method of a new structure thermoelectric element according to the first to third embodiments of the present invention. [Figure 16] FIG. 16 is a perspective view in one direction showing a number of new structure thermoelectric elements cut from (b) of FIG. 15. DETAILED DESCRIPTION OF THE INVENTION

[0031] A most preferred embodiment of the present invention is characterized by including the steps of: (a) filling a thermoelectric material powder into a spacer portion located inside a mold portion so as to surround the inside and outside of the spacer portion; (b) pressing the spacer portion with a punch portion; (c) sintering the thermoelectric material powder using spark plasma to produce a sintered body; and (d) cutting the sintered body to a predetermined size to produce a number of thermoelectric elements.

[0032] The present invention will be described below with reference to the accompanying drawings. However, the present invention may be realized in various different forms and is not limited to the embodiments described herein. In addition, in order to clearly explain the present invention in the drawings, parts that are not relevant to the description are omitted, and similar parts are designated by similar reference numerals throughout the specification.

[0033] Throughout this specification, when a part is said to be "connected (connected, contacted, or coupled)" to another part, this includes not only "directly connected" but also "indirectly connected" through another member in between. Furthermore, when a part is said to "include" a certain component, this does not mean that it excludes other components, but that it may further include other components, unless otherwise specified.

[0034] The terms used in this specification are merely used to describe specific embodiments and are not intended to limit the present invention. The singular expressions include the plural expressions unless the context clearly indicates otherwise. In this specification, the terms "comprise" or "have" are intended to specify the presence of features, numbers, steps, operations, components, parts, or combinations thereof described in the specification, and do not preclude the possibility of the presence or addition of one or more other features, numbers, steps, operations, components, parts, or combinations thereof.

[0035] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings.

[0036] 1. Mass production method for new structure thermoelectric elements 1-1. First embodiment (using one spacer portion having a rectangular parallelepiped shape) Hereinafter, a mass production method of a novel thermoelectric element according to a first embodiment of the present invention will be described with reference to FIGS. 2 to 4. A molding device for manufacturing a novel thermoelectric element and an SPS device including the molding device will be briefly described.

[0037] The molding apparatus 100 includes a molding section 110 , a punch section 120 , and a spacer section 140 .

[0038] Here, the mold part 110 may be a carbon mold.

[0039] The punch unit 120 includes an upper punch 121 and a lower punch 122 .

[0040] The molding apparatus 100 is included in the SPS apparatus 200 .

[0041] Fig. 2 is a flow chart showing a mass production method of novel structure thermoelectric elements according to the first and second embodiments of the present invention. Fig. 3 (a), (b), (c), and (d) are process flow charts conceptually showing detailed steps of a mass production method of novel structure thermoelectric elements according to the first embodiment of the present invention.

[0042] 2 and 3(a), (b), (c), and (d), the method for mass-producing novel structure thermoelectric elements according to the first embodiment of the present invention includes: (a) step S100, in which thermoelectric material powder TP is filled into spacer unit 140 located inside mold unit 110; (b) step S200, in which punch unit 120 presses spacer unit 140; (c) step S300, in which spark plasma is used to sinter thermoelectric material powder TP to produce sintered bodies 140 and 150; and (d) step S400, in which the sintered bodies are cut to a predetermined size to produce a large number of thermoelectric elements 300.

[0043] 4(a), (b), (c), (d), (e), and (f) are process flowcharts showing detailed steps of the mass production method for new structure thermoelectric elements according to the first embodiment of the present invention.

[0044] The step (a) includes: (a1) inserting the upper part of the lower punch 122 provided in the punch unit 120 into the interior of the mold unit 110; (a2) supplying thermoelectric material powder TP onto the upper surface of the lower punch 122; (a3) ​​arranging the spacer unit 140 on top of the thermoelectric material powder TP supplied onto the upper surface of the lower punch 122; (a4) supplying the thermoelectric element powder TP into the interior of the mold unit 110; and (a5) inserting the lower part of the upper punch 121 provided in the punch unit 120 into the interior of the mold unit 110.

[0045] Illustratively, mold section 110 may be a carbon mold.

[0046] 3(a) and 4(a), in step (a), the upper part of the lower punch 122 is inserted into the interior of the mold part 110. At this time, the interior of the mold part 110 is formed to correspond to the spacer part 140.

[0047] Next, referring to (b) of FIG. 4, in the step (a2), thermoelectric material powder TP is supplied to the upper surface of the lower punch 122.

[0048] Next, referring to (b) and (c) of FIG. 4, in step (a3), the spacer portion 140 is placed on top of the thermoelectric material powder TP supplied to the upper surface of the lower punch 122, so that the spacer portion 140 is positioned inside the mold portion 110.

[0049] Next, in step (a4), the spacer portion 140 may have a rectangular parallelepiped shape that is elongated in one direction.

[0050] Referring to FIGS. 3(b) and 4(c), in step (a4), the thermoelectric element powder TP is supplied into the mold part 110 so as to surround the spacer part 140.

[0051] Next, referring to FIG. 3(b) and FIG. 4(d), in the step (a5), the lower part of the upper punch 121 provided in the punch unit 120 is inserted into the mold unit 110.

[0052] Next, referring to FIG. 3(b) and FIG. 4(d), step (b) includes steps (b1) of moving the lower punch 122 upward, (b2) of moving the upper punch 121 downward, and (b3) of pressing the thermoelectric material powder TP and the spacer portion 140 by the upper punch 121 and the lower punch 122.

[0053] Next, referring to FIG. 4(e), in step (c), the SPS apparatus 200 generates spark plasma in the molding apparatus 100 to sinter the thermoelectric material powder TP, thereby producing the sintered bodies 140 and 150 shown in the upper part of FIG. 3(c) and FIG. 4(f).

[0054] Here, the sintered bodies 140 and 150 include a spacer portion 140 and a thermoelectric material portion 150 surrounding the spacer portion 140 .

[0055] Next, between steps (c) and (d), the present invention further includes a step of removing the sintered bodies 140 and 150 sintered inside the mold part 110 after the upper punch 121 and the lower punch 122 move up and down and separate from the mold part 110.

[0056] Next, referring to (d) of FIG. 3 and (f) of FIG. 4, the step (d) includes (d1) cutting the sintered bodies 140 and 150 vertically while maintaining a predetermined interval in the horizontal direction, and (d2) manufacturing a plurality of thermoelectric elements 300.

[0057] The thermoelectric element 300 includes a spacer 310 in which the spacer portion 140 is cut and a thermoelectric material 320 in which the thermoelectric material portion 150 is cut.

[0058] 1-2. Second embodiment (application of one spacer portion having many slits formed therein) Hereinafter, a mass production method of a novel thermoelectric element according to a second embodiment of the present invention will be described with reference to FIGS. 2 to 10. A molding device for manufacturing a novel thermoelectric element and an SPS device including the molding device will be briefly described.

[0059] 5(a) and 5(b) are perspective views in one direction showing a molding device for carrying out a mass production method for thermoelectric elements with a new structure according to a second embodiment of the present invention.

[0060] Referring to FIGS. 5(a) and 5(b), the molding apparatus 100 includes a molding section 110, a punch section 120, a sheet section 130, and a spacer section 140.

[0061] The molding apparatus 100 is included in the SPS apparatus 200 .

[0062] Here, the mold part 110 may be a carbon mold.

[0063] The punch section 120 includes an upper punch 121 and a lower punch 122 .

[0064] The spacer portion 140 includes a horizontal spacer 141 and a vertical spacer 142 .

[0065] Referring to FIG. 2 , the mass production method for novel thermoelectric elements according to the second embodiment of the present invention includes: (a) step S100, in which thermoelectric material powder TP is filled into spacer unit 140 located inside mold unit 110; (b) step S200, in which punch unit 120 presses spacer unit 140; (c) step S300, in which the thermoelectric material powder TP is sintered using spark plasma to produce sintered bodies 140 and 150; and (d) step S400, in which the sintered bodies are cut to a predetermined size to produce a large number of thermoelectric elements 300.

[0066] 5(a), step (a) includes the steps of: (a1) inserting an upper portion of a lower punch 122 provided in the punch unit 120 into the mold unit 110; (a2) arranging one of the plurality of sheet units 130 on the upper portion of the lower punch 122; (a3) ​​supplying thermoelectric material powder TP onto the upper surface of one of the sheet units 122; (a4) arranging a spacer unit 140 on the thermoelectric material powder TP supplied onto the upper surface of one of the sheet units 130; (a5) supplying thermoelectric element powder TP into the mold unit 110; (a6) arranging another of the plurality of sheet units 130 on the upper portion of the spacer unit 140; and (a7) inserting a lower portion of an upper punch 121 provided in the punch unit 120 into the mold unit 110.

[0067] Referring to FIG. 5(a), in the step (a2), one of the sheets 130 is disposed above the lower punch 122 and is the lowest sheet 130.

[0068] Referring to FIG. 5(a), in step (a3), before arranging the spacer portion 140, the thermoelectric material powder TP is supplied onto one of the sheet portions 130 so that the thermoelectric material powder TP can surround the spacer portion 140.

[0069] FIG. 6 is a view showing that the spacer part is fixed to the inner surface of the mold part in the mass production method of the thermoelectric element with the new structure according to the second and third embodiments of the present invention.

[0070] Referring to FIG. 6, in step (a), the spacer part 140 is fixed in close contact with the inner surface of the mold part 110 and supported by the lower punch 122 .

[0071] Referring to FIG. 5(a), next, in step (a4), the spacer part 140 is placed on the upper part of the thermoelectric element powder TP placed below.

[0072] Specifically, in step (a4), the spacer portion 140 includes a plurality of horizontal spacers 141 extending horizontally and spaced apart vertically, as shown in FIG. 6, and a pair of vertical spacers 142 extending vertically and formed at both ends of the plurality of horizontal spacers.

[0073] Next, referring to FIG. 5(a) and FIG. 6, in step (a5), the thermoelectric material powder TP is supplied into the mold part 110, filling the many slits formed between the many horizontal spacers 141 and the pair of vertical spacers 142 and surrounding the spacer part 140.

[0074] Next, referring to (a) of Figure 5, in step (a6), another sheet part 130 of the multiple sheet parts 130 is placed on top of the spacer part 140. At this time, the other sheet part 130 is the uppermost sheet part 130, facing the lowermost sheet part 130.

[0075] Referring to FIG. 5(b), in step (a7), the lower part of the upper punch 121 is inserted into the mold part 110 to prepare for pressing the thermoelectric material powder TP and the spacer part 140.

[0076] Next, referring to (b) of FIG. 5, step (b) includes: (b1) a step in which the lower punch 122 moves upward; (b2) a step in which the upper punch 121 moves downward; and (b3) a step in which the upper punch 121 and the lower punch 122 pressurize the thermoelectric material powder TP and the spacer portion 140.

[0077] Next, in step (c), the SPS apparatus 200 generates spark plasma in the molding apparatus 100 to sinter the thermoelectric material powder TP, thereby producing the sintered bodies 140 and 150 shown in the upper part of FIG. 3(c) and FIG. 4(f).

[0078] Here, the sintered bodies 140 and 150 include a spacer portion 140 and a thermoelectric material portion 150 surrounding the spacer portion 140 .

[0079] FIG. 7 is a perspective view in one direction showing a sintered body including a spacer portion and a thermoelectric element portion formed by sintering thermoelectric material powder filled to surround the inside and outside of the spacer portion, in a method for mass-producing thermoelectric elements with a new structure according to second and third embodiments of the present invention.

[0080] Next, the present invention may further include a step between steps (c) and (d) in which the upper punch 121 and the lower punch 122 move upward and downward to separate from the mold part 110, and then remove the sintered bodies 140 and 150 sintered inside the mold part 110. The sintered bodies 140 and 150 separated from the mold part 110 are shown in FIG. 7.

[0081] FIG. 8 is a view illustrating the removal of both sides of a sintered body including a spacer portion and a thermoelectric element portion formed by sintering thermoelectric material powder filled to surround the inside and outside of the spacer portion in a mass production method for a novel structure thermoelectric element according to second and third embodiments of the present invention.

[0082] FIG. 9 is a diagram illustrating the manufacturing of a large number of thermoelectric elements by cutting a sintered body formed by the method for mass-producing thermoelectric elements with a new structure according to the second and third embodiments of the present invention.

[0083] FIG. 10 is a perspective view in one direction showing a large number of thermoelectric elements manufactured by the mass manufacturing method for thermoelectric elements with a new structure according to the second and third embodiments of the present invention.

[0084] Next, referring to FIGS. 8 to 10, step (d) includes the steps of: (d1) cutting both sides of the sintered bodies 140 and 150 vertically; (d2) cutting the sintered bodies 140 and 150 horizontally while maintaining a predetermined interval in the vertical direction; (d3) cutting the sintered bodies 140 and 150 vertically while maintaining a predetermined interval in the horizontal direction; and (d4) manufacturing a plurality of thermoelectric elements 300.

[0085] Referring to FIG. 8, in step (d1), both sides of the sintered bodies 140 and 150 are cut in the vertical direction.

[0086] Next, referring to FIG. 9, in step (d2), the sintered bodies 140 and 150 are cut horizontally while maintaining a predetermined gap in the vertical direction, and in step (d3), the sintered bodies 140 and 150 are cut vertically while maintaining a predetermined gap in the horizontal direction.

[0087] Next, referring to FIG. 10, after steps (d1) to (d3), a number of thermoelectric elements 300 are manufactured in step (d4).

[0088] 1-3. Third embodiment (application of many spacer portions with many slits formed) Hereinafter, a mass production method of a novel thermoelectric element according to a third embodiment of the present invention will be described with reference to FIGS. 5 to 12. A molding device for manufacturing a novel thermoelectric element and an SPS device including the molding device will be briefly described.

[0089] The third embodiment differs from the second embodiment in that the spacer portion is made up of a large number of spacers.

[0090] The molding apparatus 100 includes a molding section 110 , a punch section 120 , a sheet section 130 , a number of spacer sections 140 , and a number of support sections 160 .

[0091] The molding apparatus 100 is included in the SPS apparatus 200 .

[0092] Here, the mold part 110 may be a carbon mold.

[0093] The punch section 120 includes an upper punch 121 and a lower punch 122 .

[0094] The spacer portion 140 includes a horizontal spacer 141 and a vertical spacer 142 .

[0095] FIG. 11 is a flow chart showing a mass production method of a new structure thermoelectric element according to a third embodiment of the present invention.

[0096] Referring to FIG. 11 , the mass production method for novel structure thermoelectric elements according to the third embodiment of the present invention includes: (a) step S100, in which thermoelectric material powder TP is filled into a plurality of spacer members 140 positioned inside a mold member 110; (b) step S200, in which a punch member 120 presses the plurality of spacer members 140; (c) step S300, in which a spark plasma sintering apparatus 200 sinters the thermoelectric material powder TP using spark plasma to produce a plurality of sintered bodies 140, 150; and (d) step S400, in which the plurality of sintered bodies 140, 150 are cut to a predetermined size to produce a plurality of thermoelectric elements.

[0097] FIG. 12 is a perspective view in one direction showing a molding device for carrying out a mass production method for thermoelectric elements with a new structure according to a third embodiment of the present invention.

[0098] Referring to FIG. 12 , step (a) includes the steps of: (a1) arranging the lowest spacer unit 140 of the plurality of spacer units 140 on top of the lower punch 122 included in the punch unit 120, and then supplying the thermoelectric material powder TP into the lowest spacer unit 140; (a2) arranging the n-layer spacer unit 140 of the plurality of spacer units 140 on top of the lowest spacer unit 140, and then supplying the thermoelectric material powder TP into the n-layer spacer unit 140; and (a3) ​​arranging the highest spacer unit 140 of the plurality of spacer units 140 on top of the n-layer spacer unit 140, and then supplying the thermoelectric material powder TP into the highest spacer unit 140.

[0099] 12, the step (a1) includes the steps of: (a11) placing the lowest sheet portion 130 of the plurality of sheet portions 130 on the upper part of the lower punch 122; (a12) supplying thermoelectric material powder TP on the upper part of the lowest sheet portion 130; (a13) placing the lowest spacer portion 140 on the thermoelectric material powder TP supplied on the upper part of the lowest sheet portion 130; (a14) supplying thermoelectric material powder TP on the upper part of the lowest spacer portion 140; (a15) placing any one of the plurality of sheet portions 130 on the thermoelectric material powder TP supplied on the upper part of the lowest spacer portion 140; and (a16) placing an n-layer support portion 160 of the plurality of support portions 160 on the upper part of any one of the sheet portions 130.

[0100] Next, referring to FIG. 12 , step (a2) includes steps of: (a21) arranging an n-layer sheet portion 130 of the plurality of sheet portions on top of an n-layer support portion 160; (a22) supplying thermoelectric material powder TP on top of the n-layer sheet portion 130; (a23) arranging an n-layer spacer portion 140 of the plurality of spacer portions 140 on top of the thermoelectric element powder TP supplied on top of the n-layer sheet portion 130; and (a24) supplying thermoelectric material powder TP on top of the n-layer spacer portion 140.

[0101] In particular, the steps (a21) to (a24) are repeated until the preset number of times reaches n (where n is a natural number).

[0102] For example, when n is 1, the first-layer support portion 160, the first-layer sheet portion 130, the thermoelectric material powder TP, the first-layer spacer portion 140, and the thermoelectric material powder TP are laminated in this order.

[0103] Next, when n is 2, the two-layer support portion 160, the two-layer sheet portion 130, the thermoelectric material powder TP, the two-layer spacer portion 140, and the thermoelectric material powder TP are laminated in this order.

[0104] Next, when n is 3, the three-layer support portion 160, the three-layer sheet portion 130, the thermoelectric material powder TP, the three-layer spacer portion 140, and the thermoelectric material powder TP are laminated in this order.

[0105] In the present invention, as shown in FIG. 12, n is illustrated as 1 to 3, whereby three sintered bodies 140, 150 are formed in step (a2), but the present invention is not limited to this.

[0106] That is, since n is a natural number, it can be changed as many times as necessary according to the user's purpose and needs.

[0107] Next, the step (a3) ​​includes the steps of (a31) arranging another one of the multiple sheet portions 130 on top of the thermoelectric material powder TP supplied on top of the n-layer spacer portion 140, (a32) supplying the thermoelectric material powder TP on top of the other one of the sheet portions 130, (a33) arranging the uppermost spacer portion 140 of the multiple spacer portions 140 on top of the thermoelectric material powder TP supplied on top of the other one of the sheet portions 130, (a34) supplying the thermoelectric material powder TP on top of the uppermost spacer portion 140, (a35) arranging the uppermost sheet portion 130 of the multiple sheet portions 130 on top of the thermoelectric material powder TP supplied on top of the uppermost spacer portion 140, and (a35) arranging the uppermost punch 121 provided in the punch unit 120 on top of the uppermost sheet portion 130.

[0108] Next, the present invention may further include a step between steps (c) and (d) in which the upper punch 121 and the lower punch 122 provided in the punch unit 120 move upward and downward to separate from the mold unit 110, and then remove the multiple sintered bodies 140, 150 sintered inside the mold unit 110. The sintered bodies 140, 150 separated from the mold unit 110 are shown in FIG. 7.

[0109] Next, referring to FIGS. 8 to 10, step (d) includes the steps of (d1) cutting the plurality of sintered bodies 140, 150 in the horizontal direction while maintaining a predetermined interval in the vertical direction, (d2) cutting the plurality of sintered bodies 140, 150 in the vertical direction while maintaining a predetermined interval in the horizontal direction, and (d3) manufacturing a plurality of thermoelectric elements TP.

[0110] Referring to FIG. 8, in step (d1), both sides of the sintered bodies 140 and 150 are cut in the vertical direction.

[0111] Next, referring to FIG. 9, in step (d2), the sintered bodies 140 and 150 are cut horizontally while maintaining a predetermined gap in the vertical direction, and in step (d3), the sintered bodies 140 and 150 are cut vertically while maintaining a predetermined gap in the horizontal direction.

[0112] Next, referring to FIG. 10, after steps (d1) to (d3), a number of thermoelectric elements 300 are manufactured in step (d4).

[0113] Figures 13(a) and (b) are graphs showing the power generation cost and temperature difference for each content of thermoelectric material.

[0114] The novel structure thermoelectric elements manufactured by the mass production method of novel structure thermoelectric elements according to the first to third embodiments of the present invention secure a similar level of power generation performance compared to existing thermoelectric elements, even though they use a spacer part and contain a smaller amount of thermoelectric material powder than conventional techniques.

[0115] The content (β) of the thermoelectric material shown in FIG. 13(a) is defined by the following [Equation 1].

[0116] [Number 1] Thermoelectric material content (%) = (total area including spacer and thermoelectric material) / total area including spacer and thermoelectric material

[0117] (Here, the spacer and thermoelectric material are shown in FIG. 4(f), FIG. 9 and FIG. 10.) As shown in FIG. 13(a), it can be seen that as the content rate (β) of the thermoelectric material increases, the power generation cost (Normalized) increases.

[0118] Furthermore, as shown in FIG. 13(b), it can be confirmed that the temperature difference increases as the content (β) of the thermoelectric material increases.

[0119] Power generation performance is determined by electron mobility, Seebeck coefficient, and temperature difference. The novel thermoelectric elements manufactured by the mass production methods for novel thermoelectric elements according to the first to third embodiments of the present invention have lower electron mobility than conventional thermoelectric elements, but have increased Seebeck coefficients and temperature differences, thereby ensuring similar power generation performance while using less thermoelectric material than conventional thermoelectric elements.

[0120] 14(a), (b), and (c) are actual photographs showing the new structure thermoelectric elements manufactured by the mass manufacturing methods of the new structure thermoelectric elements according to the first to third embodiments of the present invention.

[0121] The new structure thermoelectric elements actually manufactured by the mass production method of the new structure thermoelectric elements according to the first to third embodiments are shown in Figures 14(a), (b), and (c).

[0122] Figures 15(a), (b), and (c) are perspective views in one direction showing the sizes of sintered bodies manufactured by conventional technology and sintered bodies manufactured by the mass production methods of new structure thermoelectric elements according to the first to third embodiments of the present invention.

[0123] FIG. 15(a) is a perspective view in one direction showing the size of a sintered body produced by a conventional technique.

[0124] In FIG. 15(a), the diameter (a) of the sintered body is 12 cm to 15 cm, the height (b) of the sintered body is 2 cm to 3 cm, and the weight of the sintered body is 2 kg to 2.5 kg.

[0125] FIG. 15(b) is a perspective view in one direction showing the size of a sintered body manufactured by the mass production method for thermoelectric elements with a new structure according to the second embodiment of the present invention.

[0126] In FIG. 15(b), the horizontal length (c) of the sintered body is 3 cm, the height (d) of the sintered body is 0.6 cm, and the weight of the sintered body is 0.004 kg.

[0127] FIG. 15(c) is a perspective view in one direction showing the size of a sintered body manufactured by the mass production method for thermoelectric elements with a new structure according to the third embodiment of the present invention.

[0128] In (c) of Figure 15, the horizontal length (c) of the sintered body is 8.5 cm, the vertical length of the sintered body is 7.8 cm, the height of the sintered body is 0.4 cm, and the length (d) by which the sintered body is cut horizontally is 0.6 cm.

[0129] The circle shown in FIG. 15(c) is a sintered body manufactured by the conventional technique described in FIG. 15(a).

[0130] Considering (c) of FIG. 15, even when only the simple cross-sectional area is taken into consideration, the second embodiment of the present invention can produce approximately 273 new-structure thermoelectric elements at a time using an SPS apparatus.

[0131] Here, the size of the new structure thermoelectric element is 4 mm x 4 mm x 6 mm.

[0132] 2. New structure thermoelectric element 300 manufactured by the mass production method of new structure thermoelectric element 16(a), (b), (c), and (d) are perspective views in one direction showing a number of thermoelectric elements with a new structure obtained by cutting (b) of FIG. 15.

[0133] The novel structure thermoelectric element 300 according to the first to third embodiments of the present invention is a novel structure thermoelectric element manufactured by the mass manufacturing method of the novel structure thermoelectric element according to the first to third embodiments described above, and includes a spacer 310 and a thermoelectric material 320.

[0134] FIG. 16(a) shows sintered bodies 141 and 150, and when the sintered bodies 141 and 150 are cut, a new structure thermoelectric element 300 shown in FIG. 16(b) is formed.

[0135] Referring to FIG. 16( a ), the sintered bodies 141 and 150 include a horizontal spacer 141 and a thermoelectric element part 150 .

[0136] Specifically, the horizontal length (c) of the sintered bodies 14 and 150 is 3 cm, the vertical length (d) of the sintered bodies 14 and 150 is 0.4 cm, and the height (d) of the sintered bodies 141 and 150 is 0.6 cm.

[0137] One of the many new-structure thermoelectric elements formed by cutting the sintered bodies 141 and 150 is shown in FIG. 16(b), which is a new-structure thermoelectric element 300.

[0138] Referring to (b), (c), and (d) of FIG. 16, the spacer 310 may have a hexahedral shape.

[0139] Specifically, the horizontal length (h) of the spacer 310 is 0.4 cm, the vertical length (i) of the spacer 310 is 0.3 cm, and the height (j) of the spacer 310 is 0.5 cm.

[0140] The two opposing surfaces of the spacer 310 are exposed to the outside.

[0141] The thermoelectric material 320 is formed to surround four of the six surfaces of the spacer 310, excluding the two surfaces that face each other.

[0142] Specifically, the horizontal length (h) of the thermoelectric material 320 is 0.4 cm, the vertical length (g) of the thermoelectric material 320 is 0.4 cm, and the height (d) of the thermoelectric material 320 is 0.6 cm.

[0143] As described above, the present invention can mass-produce thermoelectric elements in a single process using an SPS apparatus, compared to the prior art.

[0144] The above description of the present invention is for illustrative purposes only, and those skilled in the art will understand that the present invention can be easily modified into other specific forms without changing the technical spirit or essential features of the present invention. Therefore, the above-described embodiments are illustrative in all respects and not limiting. For example, each component described as a single component may be implemented in a distributed form, and similarly, each component described as a distributed component may be implemented in a combined form.

[0145] The scope of the present invention is defined by the claims that follow, and all modifications and variations that fall within the meaning and scope of the claims and their equivalents are included within the scope of the present invention.

Claims

1. (a) filling a thermoelectric material powder into a spacer portion located inside a mold portion so as to surround the inside and outside of the spacer portion; (b) a step in which the punch portion presses the spacer portion; (c) sintering the thermoelectric material powder using spark plasma to form a sintered body; and (d) cutting the sintered body into a predetermined size to manufacture a number of thermoelectric elements; A mass production method for a new structure thermoelectric element.

2. (a) filling a thermoelectric material powder so as to surround the inside and outside of a number of spacer portions located inside a mold portion; (b) a punch portion pressing the plurality of spacer portions; (c) using a spark plasma sintering device to sinter the thermoelectric material powder using spark plasma to generate a number of sintered bodies; and (d) cutting the plurality of sintered bodies into a predetermined size to manufacture a plurality of thermoelectric elements; A mass production method for a new structure thermoelectric element.

3. The step (a) includes: (a1) inserting an upper portion of a lower punch provided in the punch unit into the mold unit; (a2) supplying the thermoelectric material powder onto the upper surface of the lower punch; (a3) placing the spacer portion on top of the thermoelectric material powder supplied to the upper surface of the lower punch; (a4) supplying the thermoelectric element powder into the mold part; and (a5) inserting a lower portion of an upper punch provided in the punch section into the inside of the mold section; A method for mass-producing the thermoelectric element of the new structure according to claim 1.

4. The step (a) includes: (a1) inserting an upper portion of a lower punch provided in the punch unit into the mold unit; (a2) placing one of the plurality of sheet portions on the upper portion of the lower punch; (a3) supplying the thermoelectric material powder onto an upper surface of any one of the sheet portions; (a4) disposing the spacer portion on top of the thermoelectric material powder supplied on the upper surface of any one of the sheet portions; (a5) supplying the thermoelectric element powder into the mold part; (a6) placing another sheet portion of the plurality of sheet portions on top of the spacer portion; and (a7) inserting a lower portion of an upper punch provided in the punch section into the inside of the mold section; A method for mass-producing the thermoelectric element of the new structure according to claim 1.

5. In the step (a4), The spacer portion has a rectangular parallelepiped shape that extends long in one direction, In the step (a4), the thermoelectric element powder is supplied into the mold part to surround the spacer part. A method for mass-producing the thermoelectric element of the new structure according to claim 3.

6. In the step (a4), The spacer portion is a number of horizontal spacers extending laterally and spaced apart from one another in the vertical direction; and a pair of vertical spacers extending longitudinally and formed at both ends of the plurality of horizontal spacers; In the step (a5), the thermoelectric material powder is supplied into the mold portion, filling the many slits formed between the many horizontal spacers and the pair of vertical spacers, and surrounding the spacer portion. A method for mass-producing the thermoelectric element of the new structure according to claim 4.

7. The step (a) includes: (a1) placing a lowest spacer portion among the plurality of spacer portions on an upper portion of a lower punch provided in the punch unit, and then supplying the thermoelectric material powder into the lowest spacer portion; (a2) disposing an n-layer spacer portion among the plurality of spacer portions on top of the lowest spacer portion, and then supplying thermoelectric material powder into the n-layer spacer portion; and (a3) disposing an uppermost spacer portion among the plurality of spacer portions on top of the n-layer spacer portion, and then supplying thermoelectric material powder into the uppermost spacer portion; A method for mass-producing the thermoelectric element of the new structure according to claim 2.

8. The step (a1) (a11) placing the lowest sheet portion among the plurality of sheet portions on the upper portion of the lower punch; (a12) supplying the thermoelectric material powder onto the lowermost sheet portion; (a13) placing the spacer portion located at the bottom on top of the thermoelectric material powder supplied on top of the sheet portion located at the bottom; (a14) supplying the thermoelectric material powder onto an upper portion of the spacer portion located at the bottom; (a15) disposing one of the plurality of sheet portions on top of the thermoelectric material powder supplied on top of the spacer portion located at the bottom; and (a16) disposing n-layer support portions among the plurality of support portions on the upper portion of any one of the sheet portions; A method for mass-producing the thermoelectric element of the new structure according to claim 7.

9. The step (a2) (a21) placing an n-layer sheet portion among the plurality of sheet portions on the upper portion of the n-layer support portion; (a22) supplying the thermoelectric material powder onto the top of the n-layer sheet portion; (a23) arranging an n-layer spacer portion among the plurality of spacer portions on top of the thermoelectric element powder supplied on top of the n-layer sheet portion; and (a24) supplying the thermoelectric material powder onto an upper portion of the n-layer spacer portion; The steps (a21) to (a24) are repeated until the preset number of times reaches n (n=natural number). A method for mass-producing the thermoelectric element of the new structure according to claim 8.

10. The step (a3) (a31) placing another sheet portion of the plurality of sheet portions on top of the thermoelectric material powder supplied on top of the n-layer spacer portion; (a32) supplying the thermoelectric material powder onto the other sheet portion; (a33) placing the uppermost spacer portion among the plurality of spacer portions on top of the thermoelectric material powder supplied on top of the other sheet portion; (a34) supplying the thermoelectric material powder onto the uppermost spacer portion; (a35) placing the uppermost sheet portion of the plurality of sheet portions on top of the thermoelectric material powder supplied on top of the uppermost spacer portion; and (a35) a step in which an upper punch provided in the punch unit is disposed above the uppermost sheet unit; A method for mass-producing the thermoelectric element of the new structure according to claim 9.

11. Between the step (c) and the step (d), and removing the plurality of sintered bodies sintered inside the mold unit after the upper punch and the lower punch provided in the punch unit move upward and downward to separate from the mold unit. A method for mass-producing the thermoelectric element of the new structure according to claim 2.

12. Between the step (c) and the step (d), and removing the sintered body sintered inside the mold part after the upper punch and the lower punch are moved upward and downward and separated from the mold part. The method for mass-producing the novel thermoelectric element according to claim 3 or 4.

13. The step (d) includes: (d1) cutting both sides of the multiple sintered bodies in the longitudinal direction; (d2) cutting the plurality of sintered bodies in the horizontal direction while maintaining predetermined intervals in the vertical direction; (d3) cutting the plurality of sintered bodies in the vertical direction while maintaining a predetermined interval in the horizontal direction; and (d4) the step of fabricating the plurality of thermoelectric elements; A method for mass-producing the thermoelectric element of the new structure according to claim 2.

14. The step (d) includes: (d1) cutting the sintered body in the vertical direction while maintaining a predetermined interval in the horizontal direction; and (d2) the step of fabricating the plurality of thermoelectric elements; A method for mass-producing the thermoelectric element of the new structure according to claim 3.

15. The step (d) includes: (d1) cutting both sides of the sintered body in the longitudinal direction; (d2) cutting the sintered body in the horizontal direction while maintaining a predetermined interval in the vertical direction; (d3) cutting the sintered body in the vertical direction while maintaining a predetermined interval in the horizontal direction; and (d4) the step of fabricating the plurality of thermoelectric elements; A method for mass-producing the thermoelectric element of the new structure according to claim 4.

16. A new structure thermoelectric element manufactured by the mass production method of the new structure thermoelectric element according to any one of claims 1, 3 and 4, a hexahedron-shaped spacer; and a thermoelectric material surrounding four of the six surfaces of the spacer, excluding two surfaces facing each other; The two opposing surfaces of the spacer are exposed to the outside. A thermoelectric element with a new structure.

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