Mass production method for novel 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 method for mass-producing a new-structured thermoelectric element. More specifically, the present invention relates to a method for mass-producing a new-structured thermoelectric element that mixes a thermoelectric material powder and a spacer part to mass-produce thermoelectric elements while reducing production costs.

Background Art

[0002] A thermoelectric element is classified as one of the energy harvesting devices. A thermoelectric element typically includes a heat source, a heat sink, and a thermocouple array. The thermocouple array is composed of a plurality of thermocouples connected in series and is used to convert a part of the thermal energy into energy.

[0003] Generally, a thermoelectric element is formed using a semiconductor material. The semiconductor materials are electrically connected in series and thermally connected in parallel to form two junctions in order to form a thermocouple. Typically, there are N-type and P-type semiconductor materials. In a typical thermoelectric element, an electrically conductive connection 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 to induce an electric current.

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

[0005] According to the prior art illustrated in Figures 1(a) and 1(b), after manufacturing a sintered body using an SPS device, it is cut to a predetermined size to manufacture a thermoelectric element.

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

[0007] Referring to Figure 1(b), the diameter (a) of the sintered body manufactured by the aforementioned prior art 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 aforementioned conventional technology is disadvantageous in terms of cost because the sintered body is made entirely of thermoelectric material, and it also has the problem that the outer part must be discarded during cutting because the sintered body is formed in a circular shape. [Prior art documents] [Patent Documents]

[0009] [Patent Document 1] Korean Registered Patent No. 10-1152222 (May 25, 2012) [Overview of the project] [Problems that the invention aims to solve]

[0010] The objective of the present invention to solve the aforementioned problems is to provide a method for mass-producing a new structured thermoelectric element, which involves mixing thermoelectric material powder and a spacer part, then sintering the mixture using an SPS apparatus to produce a sintered body, and finally cutting the resulting sintered body to produce a large quantity of thermoelectric elements in a single process.

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

[0012] To achieve the above-mentioned objectives, the present invention provides a method for mass-producing a novel thermoelectric element, characterized by comprising: (a) filling the mold portion with thermoelectric material powder so as to surround the inside and outside of a spacer portion located inside the mold portion; (b) pressurizing 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] Furthermore, the present invention provides a method for mass-producing a novel thermoelectric element, characterized by the configuration for achieving the above-mentioned objectives, which includes: (a) filling a mold portion with thermoelectric material powder so as to surround the inside and outside of a plurality of spacer portions located inside the mold portion; (b) pressing the plurality of spacer portions with a punch portion; (c) using a spark plasma sintering apparatus to sinter the thermoelectric material powder using spark plasma to produce a plurality of sintered bodies; and (d) cutting the plurality of sintered bodies to a predetermined size to produce a plurality of thermoelectric elements.

[0014] In embodiments of the present invention, step (a) may include (a1) inserting the upper part of the lower punch provided in the punch section into the mold section; (a2) supplying the thermoelectric material powder to the upper surface of the lower punch; (a3) ​​positioning the spacer section 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 section; and (a5) inserting the lower part of the upper punch provided in the punch section into the mold section.

[0015] In embodiments of the present invention, step (a) may include (a1) inserting the upper part of the lower punch provided in the punch section into the mold section; (a2) placing one of the numerous sheet sections on the upper part of the lower punch; (a3) ​​supplying the thermoelectric material powder to the upper surface of the one of the sheet sections; (a4) placing the spacer section on top of the thermoelectric material powder supplied to the upper surface of the one of the sheet sections; (a5) supplying the thermoelectric element powder into the mold section; (a6) placing another sheet section from the numerous sheet sections on top of the spacer section; and (a7) inserting the lower part of the upper punch provided in the punch section into the mold section.

[0016] In embodiments of the present invention, in step (a4), the spacer portion has a rectangular parallelepiped shape that extends long in one direction, and in step (a4), the thermoelectric element powder is supplied into the mold portion, thereby surrounding the spacer portion.

[0017] In embodiments of the present invention, in step (a4), the spacer portion includes a plurality of horizontal spacers that are elongated in the lateral direction and arranged to be spaced apart from each other in the vertical direction; and a pair of vertical spacers that are elongated in the vertical direction and formed at each end of the plurality of horizontal spacers, and in step (a5), the thermoelectric material powder is supplied into the mold portion so as to fill a plurality of slits formed between the plurality of horizontal spacers and the pair of vertical spacers, thereby surrounding the spacer portion.

[0018] In embodiments of the present invention, step (a) may include (a1) a step in which the lowest spacer portion among the numerous spacer portions is placed on the upper part of the lower punch provided in the punch portion, and then the thermoelectric material powder is supplied to the interior of the lowest spacer portion; (a2) a step in which an n-layer spacer portion among the numerous spacer portions is placed on the upper part of the lowest spacer portion, and then the thermoelectric material powder is supplied to the interior of the n-layer spacer portion; and (a3) ​​a step in which the uppermost spacer portion among the numerous spacer portions is placed on the upper part of the n-layer spacer portion, and then the thermoelectric material powder is supplied to the interior of the uppermost spacer portion.

[0019] In embodiments of the present invention, step (a1) may include (a11) a step in which the lowest sheet portion among the plurality of sheet portions is positioned on top of the lower punch; (a12) a step in which the thermoelectric material powder is supplied on top of the lowest sheet portion; (a13) a step in which the lowest spacer portion is positioned on top of the thermoelectric material powder supplied on top of the lowest sheet portion; (a14) a step in which the thermoelectric material powder is supplied on top of the lowest spacer portion; (a15) a step in which any one of the plurality of sheet portions is positioned on top of the thermoelectric material powder supplied on top of the lowest spacer portion; and (a16) a step in which an n-layer support portion among the plurality of support portions is positioned on top of any one of the sheet portions.

[0020] In an embodiment of the present invention, step (a2) includes (a21) a step in which an n-layer sheet portion is placed on top of the n-layer support portion from among the numerous sheet portions; (a22) a step in which the thermoelectric material powder is supplied on top of the n-layer sheet portion; (a23) a step in which an n-layer spacer portion is placed on top of the thermoelectric element powder supplied on top of the n-layer sheet portion from among the numerous spacer portions; and (a24) a step in which the thermoelectric material powder is supplied on top of the n-layer spacer portion, wherein steps (a21) to (a24) are repeated until a predetermined number of times reaches n. (where n = a natural number)

[0021] In embodiments of the present invention, step (a3) ​​may include (a31) a step in which one of the plurality of sheet portions is positioned on top of the thermoelectric material powder supplied to the top of the n-layer spacer portion; (a32) a step in which the thermoelectric material powder is supplied to the top of the other sheet portion; (a33) a step in which the uppermost spacer portion of the plurality of spacer portions is positioned on top of the thermoelectric material powder supplied to the top of the other sheet portion; (a34) a step in which the thermoelectric material powder is supplied to the top of the uppermost spacer portion; (a35) a step in which the uppermost sheet portion of the plurality of sheet portions is positioned on top of the thermoelectric material powder supplied to the top of the uppermost spacer portion; and (a35) a step in which the upper punch provided in the punch portion is positioned on top of the uppermost sheet portion.

[0022] In embodiments of the present invention, the present invention may further include a step between step (c) and step (d) of removing the numerous sintered bodies sintered inside the mold portion after the upper punch and lower punch provided in the punch portion have moved to the upper and lower parts and separated from the mold portion.

[0023] In an embodiment of the present invention, between the step (c) and the step (d), after the upper punch and the lower punch move upward and downward and are separated from the mold part, a step of taking out the sintered body sintered inside the mold part; can be further included.

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

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

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

[0027] Further, a configuration of the present invention for achieving the above object is a new structure thermoelectric element manufactured by the method for mass-producing a new structure thermoelectric element as described above, including: a hexahedron-shaped spacer; and a thermoelectric material surrounding four surfaces of the six surfaces of the spacer except for two mutually opposed surfaces, wherein the two mutually opposed surfaces of the spacer are exposed to the outside.

Effect of the Invention

[0028] The advantages of the present invention with the above-described configuration are that, after mixing the thermoelectric material powder and the spacer portion, a sintered body is produced by using an SPS device, and the produced sintered body is cut to produce a large quantity of thermoelectric elements in a single process. Furthermore, production costs can be reduced by reducing the content of the thermoelectric material powder.

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

[0030] [Figure 1] This is a one-way perspective view showing the configuration for manufacturing a sintered body using conventional technology and the resulting sintered body. [Figure 2] This is a sequence diagram showing a method for mass-producing novel thermoelectric elements with a new structure according to the first and second embodiments of the present invention. [Figure 3] This is a process flowchart conceptually illustrating the detailed process of a mass manufacturing method for a novel thermoelectric element with a new structure according to the first embodiment of the present invention. [Figure 4] This is a process flowchart showing the detailed steps of a method for mass-producing a novel thermoelectric element with a new structure according to the first embodiment of the present invention. [Figure 5] This is a one-way perspective view showing a molding apparatus for mass-producing a novel thermoelectric element with a new structure according to the second embodiment of the present invention. [Figure 6] This drawing shows how the spacer portion is fixed to the inner surface of the mold portion in a mass manufacturing method of a novel thermoelectric element with a new structure according to the second and third embodiments of the present invention. [Figure 7] This is a perspective view in one direction showing a sintered body including a spacer portion and a thermoelectric element portion in which thermoelectric material powder is sintered, in accordance with the mass manufacturing method of a novel structure thermoelectric element according to the second and third embodiments of the present invention. [Figure 8]This drawing shows a method for mass-producing a novel thermoelectric element structure according to the second and third embodiments of the present invention, in which both sides of a sintered body, including a spacer portion and a thermoelectric element portion filled with thermoelectric material powder surrounding the inside and outside of the spacer portion, are removed. [Figure 9] This drawing shows how to manufacture a large number of thermoelectric elements by cutting a sintered body formed by a mass manufacturing method for a novel structure thermoelectric element according to the second and third embodiments of the present invention. [Figure 10] This is a one-way perspective view showing a large number of thermoelectric elements manufactured by a mass production method for novel thermoelectric elements according to the second and third embodiments of the present invention. [Figure 11] This is a sequence diagram showing a method for mass-producing a novel thermoelectric element with a new structure according to the third embodiment of the present invention. [Figure 12] This is a one-way perspective view showing a molding apparatus for mass-producing a novel thermoelectric element with a new structure according to the third embodiment of the present invention. [Figure 13] This graph shows the power generation cost and temperature difference based on the content of thermoelectric materials. [Figure 14] This is an actual photograph showing a novel thermoelectric element manufactured by a mass production method for novel thermoelectric elements according to the first to third embodiments of the present invention. [Figure 15] This is a one-way perspective view showing the sizes of a sintered body manufactured by conventional technology and a sintered body manufactured by a mass production method for a novel structure thermoelectric element according to the first to third embodiments of the present invention. [Figure 16] Figure 15(b) is a one-way perspective view showing numerous newly constructed thermoelectric elements cut from the original. [Modes for carrying out the invention]

[0031] One most preferred embodiment of the present invention is characterized by comprising: (a) filling the inside and outside of a spacer portion located inside a mold portion with thermoelectric material powder; (b) pressurizing 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 manufacture a number of thermoelectric elements.

[0032] The present invention will be described below with reference to the attached drawings. However, the present invention can be realized in various different forms and is therefore not limited to the embodiments described herein. Furthermore, in order to clearly illustrate the present invention with the drawings, parts unrelated to the description have been omitted, and similar parts throughout the specification are denoted by similar reference numerals.

[0033] Throughout the specification, when a part is described as being "connected (linked, in contact with, joined)" to another part, this includes not only cases where they are "directly connected" but also cases where they are "indirectly connected" with other components in between. Furthermore, when a part is described as "containing" a certain component, this does not mean that it excludes other components, but rather that it may further contain other components, unless otherwise stated.

[0034] The terms used herein are used solely to describe specific embodiments and are not intended to limit the invention. Singular expressions include plural expressions unless the context clearly indicates otherwise. In this specification, terms such as “includes” or “having” are intended to indicate the presence of features, figures, steps, actions, 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, figures, steps, actions, components, parts, or combinations thereof.

[0035] The embodiments of the present invention will be described in detail below with reference to the attached drawings.

[0036] 1. Mass production method for novel thermoelectric elements 1-1. First Embodiment (Application of a single spacer having a rectangular parallelepiped shape) The following describes a method for mass-producing a novel thermoelectric element with a new structure according to the first embodiment of the present invention, with reference to Figures 2 to 4. A molding apparatus for manufacturing the novel thermoelectric element and an SPS apparatus including the same will be briefly described.

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

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

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

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

[0041] Figure 2 is a sequence diagram showing a mass manufacturing method for novel thermoelectric elements with a new structure according to the first and second embodiments of the present invention. Figures 3(a), (b), (c), and (d) are conceptual process flowcharts showing the detailed process of the mass manufacturing method for novel thermoelectric elements with a new structure according to the first embodiment of the present invention.

[0042] Referring to (a), (b), (c), and (d) in Figures 2 and 3, a method for mass-producing a novel thermoelectric element with a new structure according to the first embodiment of the present invention includes: (a) step S100 in which thermoelectric material powder TP is filled into the spacer portion 140 located inside the mold portion 110; (b) step S200 in which the punch portion 120 pressurizes the spacer portion 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.

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

[0044] Step (a) includes (a1) inserting the upper part of the lower punch 122 provided in the punch section 120 into the mold section 110; (a2) supplying thermoelectric material powder TP to the upper surface of the lower punch 122; (a3) ​​positioning the spacer section 140 on top of the thermoelectric material powder TP supplied to the upper surface of the lower punch 122; (a4) supplying thermoelectric element powder TP into the mold section 110; and (a5) inserting the lower part of the upper punch 121 provided in the punch section 120 into the mold section 110.

[0045] For example, the mold portion 110 may be a carbon mold.

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

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

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

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

[0050] Referring to Figures 3(b) and 4(c), in step (a4), the thermoelectric element powder TP is supplied into the mold portion 110, thereby surrounding the spacer portion 140.

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

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

[0053] Next, referring to Figure 4(e), in step (c), the SPS apparatus 200 provides spark plasma to the molding apparatus 100 to sinter the thermoelectric material powder TP, thereby producing the sintered bodies 140 and 150 shown at the top of Figures 3(c) and 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, the present invention further includes a step between step (c) and step (d) of removing the sintered bodies 140 and 150 that have been sintered inside the mold section 110, after the upper punch 121 and lower punch 122 have moved to the upper and lower parts and separated from the mold section 110.

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

[0057] The thermoelectric element 300 includes a spacer 310 with a cut spacer portion 140 and a thermoelectric material 320 with a cut thermoelectric material portion 150.

[0058] 1-2. Second Embodiment (Application of a single spacer section with multiple slits) The following describes a method for mass-producing a novel thermoelectric element with a new structure according to a second embodiment of the present invention, with reference to Figures 2 to 10. A molding apparatus for manufacturing the novel thermoelectric element and an SPS apparatus including the same will be briefly described.

[0059] Figures 5(a) and 5(b) are one-way perspective views showing a molding apparatus for mass-producing a novel thermoelectric element with a new structure according to the second embodiment of the present invention.

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

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

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

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

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

[0065] Referring to Figure 2, a mass production method for a novel thermoelectric element with a new structure according to the second embodiment of the present invention includes (a) step S100 in which thermoelectric material powder TP is filled into the spacer portion 140 located inside the mold portion 110, (b) step S200 in which the punch portion 120 pressurizes the spacer portion 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] Referring to Figure 5(a), step (a) includes (a1) inserting the upper part of the lower punch 122 provided in the punch section 120 into the mold section 110, (a2) positioning one of the numerous sheet sections 130 on top of the lower punch 122, (a3) ​​supplying thermoelectric material powder TP to the upper surface of one of the sheet sections 122, (a4) positioning a spacer section 140 on top of the thermoelectric material powder TP supplied to the upper surface of one of the sheet sections 130, (a5) supplying thermoelectric element powder TP into the mold section 110, (a6) positioning another sheet section 130 from the numerous sheet sections 130 on top of the spacer section 140, and (a7) inserting the lower part of the upper punch 121 provided in the punch section 120 into the mold section 110.

[0067] Referring to Figure 5(a), in step (a2), one of the sheet portions 130 is positioned above the lower punch 122 and is the lowest sheet portion 130.

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

[0069] Figure 6 is a diagram showing how the spacer portion is fixed to the inner surface of the mold portion in a mass manufacturing method of a novel thermoelectric element with a new structure according to the second and third embodiments of the present invention.

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

[0071] Referring to Figure 5(a), in step (a4), the spacer portion 140 is then positioned on top of the thermoelectric element powder TP located at the bottom.

[0072] Specifically, in step (a4) above, the spacer portion 140 includes a number of horizontal spacers 141 that are elongated in the lateral direction and spaced apart from each other in the vertical direction, and a pair of vertical spacers 142 that are elongated in the vertical direction and formed at both ends of the number of horizontal spacers, as shown in Figure 6.

[0073] Next, referring to Figures 5(a) and 6, in step (a5), the thermoelectric material powder TP is supplied into the mold portion 110 and fills the numerous slits formed between the numerous lateral spacers 141 and the pair of vertical spacers 142, surrounding the spacer portion 140.

[0074] Next, referring to Figure 5(a), in step (a6), one of the many sheet portions 130 is positioned on top of the spacer portion 140. At this time, the other sheet portion 130 is opposite the lowest sheet portion 130 and is the uppermost sheet portion 130.

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

[0076] Next, referring to Figure 5(b), 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 provides spark plasma to 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 Figures 3(c) and 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] Figure 7 is a one-way perspective view showing a sintered body including a spacer portion and a thermoelectric element portion in which thermoelectric material powder is sintered to surround the inside and outside of the spacer portion, according to the mass manufacturing method of the novel structure thermoelectric element according to the second and third embodiments of the present invention.

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

[0081] Figure 8 is a diagram illustrating a mass manufacturing method for a novel thermoelectric element structure according to the second and third embodiments of the present invention, in which both sides of the sintered body, which includes a spacer portion and a thermoelectric element portion filled with thermoelectric material powder surrounding the inside and outside of the spacer portion, are removed.

[0082] Figure 9 is a diagram illustrating the process of manufacturing a large number of thermoelectric elements by cutting a sintered body formed by a mass manufacturing method for a novel structure thermoelectric element according to the second and third embodiments of the present invention.

[0083] Figure 10 is a one-way perspective view showing a number of thermoelectric elements manufactured by a mass production method for novel structure thermoelectric elements according to the second and third embodiments of the present invention.

[0084] Next, referring to Figures 8 to 10, step (d) includes (d1) cutting both sides of the sintered bodies 140 and 150 in the longitudinal direction, (d2) cutting the sintered bodies 140 and 150 in the transverse direction while maintaining a predetermined interval in the longitudinal direction, (d3) cutting the sintered bodies 140 and 150 in the longitudinal direction while maintaining a predetermined interval in the transverse direction, and (d4) manufacturing a number of thermoelectric elements 300.

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

[0086] Next, referring to Figure 9, in step (d2), the sintered bodies 140 and 150 are cut in the transverse direction while maintaining a predetermined interval in the longitudinal direction, and in step (d3), the sintered bodies 140 and 150 are cut in the longitudinal direction while maintaining a predetermined interval in the transverse direction.

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

[0088] 1-3. Third Embodiment (Application of Multiple Spacer Sections with Multiple Slits) The following describes a method for mass-producing a novel thermoelectric element with a new structure according to the third embodiment of the present invention, with reference to Figures 5 to 12. A molding apparatus for manufacturing the novel thermoelectric element and an SPS apparatus including the same will be briefly described.

[0089] The third embodiment differs from the second embodiment in that it is composed of a large number of spacer sections.

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

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

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

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

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

[0095] Figure 11 is a sequence diagram showing a method for mass-producing a novel thermoelectric element with a new structure according to the third embodiment of the present invention.

[0096] Referring to Figure 11, a method for mass-producing a novel thermoelectric element with a new structure according to the third embodiment of the present invention includes: (a) step S100 in which thermoelectric material powder TP is filled into a number of spacer parts 140 located inside a mold part 110; (b) step S200 in which a punch part 120 pressurizes the number of spacer parts 140; (c) step S300 in which a spark plasma sintering apparatus 200 uses spark plasma to sinter the thermoelectric material powder TP to produce a number of sintered bodies 140, 150; and (d) step S400 in which the number of sintered bodies 140, 150 are cut to a predetermined size to produce a number of thermoelectric elements.

[0097] Figure 12 is a one-way perspective view showing a molding apparatus for mass-producing a novel thermoelectric element with a new structure according to the third embodiment of the present invention.

[0098] Referring to Figure 12, step (a) includes (a1) a step in which the lowest spacer portion 140 among a number of spacer portions 140 is placed on top of the lower punch 122 provided in the punch portion 120, and then the thermoelectric material powder TP is supplied to the interior of the lowest spacer portion 140; (a2) a step in which an n-layer spacer portion 140 among a number of spacer portions 140 is placed on top of the lowest spacer portion 140, and then the thermoelectric material powder is supplied to the interior of the n-layer spacer portion 140; and (a3) ​​a step in which the uppermost spacer portion 140 among a number of spacer portions 140 is placed on top of the n-layer spacer portion 140, and then the thermoelectric material powder TP is supplied to the interior of the uppermost spacer portion 140.

[0099] Referring to Figure 12, step (a1) includes (a11) placing the lowest sheet portion 130 among the numerous sheet portions 130 on top of the lower punch 122, (a12) supplying thermoelectric material powder TP to the top of the lowest sheet portion 130, (a13) placing the lowest spacer portion 140 on top of the thermoelectric material powder TP supplied to the top of the lowest sheet portion 130, (a14) supplying thermoelectric material powder TP to the top of the lowest spacer portion 140, (a15) placing any one of the numerous sheet portions 130 on top of the thermoelectric material powder TP supplied to the top of the lowest spacer portion 140, and (a16) placing an n-layer support portion 160 among the numerous support portions 160 on top of any one sheet portion 130.

[0100] Next, referring to Figure 12, step (a2) includes (a21) a step in which an n-layer sheet portion 130 is placed on top of the n-layer support portion 160 from among a number of sheet portions, (a22) a step in which thermoelectric material powder TP is supplied on top of the n-layer sheet portion 130, (a23) a step in which an n-layer spacer portion 140 is placed on top of the thermoelectric element powder TP supplied on top of the n-layer sheet portion 130 from among a number of spacer portions 140, and (a24) a step in which thermoelectric material powder TP is supplied on top of the n-layer spacer portion 140.

[0101] In particular, steps (a21) through (a24) are repeated until the number of times that has been set is n (where n = a natural number).

[0102] For example, if n is 1, the layers are stacked in the following order: 1-layer support section 160, 1-layer sheet section 130, thermoelectric material powder TP, 1-layer spacer section 140, and thermoelectric material powder TP.

[0103] Next, if n is 2, the layers are stacked in the following order: 2-layer support section 160, 2-layer sheet section 130, thermoelectric material powder TP, 2-layer spacer section 140, and thermoelectric material powder TP.

[0104] Next, if n is 3, the layers are stacked in the following order: 3-layer support section 160, 3-layer sheet section 130, thermoelectric material powder TP, 3-layer spacer section 140, and thermoelectric material powder TP.

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

[0106] In other words, since n is a natural number, it can be changed and applied in any way that suits the user's purpose and needs.

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

[0108] Next, the present invention may further include a step between step (c) and step (d) in which the upper punch 121 and lower punch 122 provided in the punch section 120 move to the upper and lower parts and separate from the mold section 110, and then remove the numerous sintered bodies 140, 150 that have been sintered inside the mold section 110, the sintered bodies 140, 150 separated from the mold section 110 are shown in Figure 7.

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

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

[0111] Next, referring to Figure 9, in step (d2), the sintered bodies 140 and 150 are cut in the transverse direction while maintaining a predetermined interval in the longitudinal direction, and in step (d3), the sintered bodies 140 and 150 are cut in the longitudinal direction while maintaining a predetermined interval in the transverse direction.

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

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

[0114] The new structure thermoelectric element manufactured by the mass production method for the new structure thermoelectric element according to the first to third embodiments of the present invention ensures a similar level of power generation performance to existing thermoelectric elements, even while incorporating a spacer portion and slightly more thermoelectric material powder than in the conventional technology.

[0115] The thermoelectric material content (β) shown in Figure 13(a) is defined as shown in [Equation 1] below.

[0116] [Mathematics 1] Thermoelectric material content (%) = (Total area of ​​spacer and thermoelectric material) / Total area of ​​spacer and thermoelectric material

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

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

[0119] While power generation performance is determined by electron transfer, Seebeck coefficient, and temperature difference, the new structure thermoelectric elements manufactured by the mass production method for the new structure thermoelectric elements according to the first to third embodiments of the present invention have lower electron transfer than conventional thermoelectric elements, but increase the Seebeck coefficient and temperature difference, thereby enabling similar power generation performance to be achieved while using less thermoelectric material than conventional thermoelectric elements.

[0120] Figures 14(a), (b), and (c) are actual photographs showing novel thermoelectric elements manufactured by the mass production method for novel thermoelectric elements according to the first to third embodiments of the present invention.

[0121] Figures 14(a), (b), and (c) show examples of the new structure thermoelectric elements actually manufactured by the mass production method for the new structure thermoelectric elements according to the first to third embodiments described above.

[0122] Figures 15(a), (b), and (c) are one-way perspective views showing the sizes of sintered bodies manufactured by the prior art and sintered bodies manufactured by the mass production method for novel structure thermoelectric elements according to the first to third embodiments of the present invention.

[0123] Figure 15(a) is a one-directional perspective view showing the size of a sintered body manufactured by the prior art.

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

[0125] Figure 15(b) is a one-way perspective view showing the size of a sintered body manufactured by the mass production method for a novel structure thermoelectric element according to the second embodiment of the present invention.

[0126] In Figure 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] Figure 15(c) is a one-way perspective view showing the size of a sintered body manufactured by the mass production method for a novel thermoelectric element according to the third embodiment of the present invention.

[0128] In Figure 15(c), 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 of the sintered body cut horizontally (d) is 0.6 cm.

[0129] Furthermore, the circular shape shown in Figure 15(c) is a sintered body manufactured by the conventional technology described in Figure 15(a).

[0130] Considering Figure 15(c), even by considering only the simple cross-sectional area, the second embodiment of the present invention can produce approximately 273 new structure thermoelectric elements at once using an SPS device.

[0131] Here, the dimensions of the new thermoelectric element are 4mm x 4mm x 6mm.

[0132] 2. 300 new structure thermoelectric elements manufactured by a mass production method for new structure thermoelectric elements. Figures 16(a), (b), (c), and (d) are one-way perspective views showing numerous novel thermoelectric elements cut from Figure 15(b).

[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 production 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] Figure 16(a) shows sintered bodies 141 and 150, and by cutting the sintered bodies 141 and 150, the new structure thermoelectric element 300 shown in Figure 16(b) is formed.

[0135] Referring to Figure 16(a), the sintered bodies 141 and 150 include the lateral spacer 141 and the thermoelectric element section 150.

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

[0137] One of the numerous new structure thermoelectric elements formed by cutting the aforementioned sintered bodies 141 and 150 is shown in Figure 16(b).

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

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

[0140] The two opposing surfaces of the aforementioned 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] Thus, the present invention as described above allows for the mass production of thermoelectric elements in a single process using an SPS device, compared to the conventional technology.

[0144] The foregoing description of the present invention is illustrative, and a person with ordinary skill in the art to which the present invention pertains will understand that the invention can be easily modified into other specific forms without altering the technical idea or essential features. Therefore, the embodiments described above are illustrative in all respects and not limiting. For example, each component described as a single type can be implemented in a distributed manner, and similarly, components described as distributed can be implemented in a combined manner.

[0145] The scope of the present invention is defined by the claims described below, and all modifications or alterations derived from the meaning and scope of the claims and the concept of equivalents thereof are included within the scope of the present invention.

Claims

1. (a) A step in which thermoelectric material powder is filled so as to surround the inside and outside of the spacer portion located inside the mold portion; (b) A step in which the punching part pressurizes the spacer part; (c) A step of sintering the thermoelectric material powder using spark plasma to produce a sintered body; and, (d) The sintered body is cut to a predetermined size to produce a number of thermoelectric elements; A method for mass-producing a novel thermoelectric element with a unique structure.

2. (a) A step in which thermoelectric material powder is filled so as to surround the inside and outside of a number of spacer portions located inside the mold portion; (b) The punching portion pressurizes the plurality of spacer portions; (c) A spark plasma sintering apparatus uses spark plasma to sinter the thermoelectric material powder and produce a number of sintered bodies; and, (d) The step of cutting the numerous sintered bodies into predetermined sizes to manufacture a number of thermoelectric elements; A method for mass-producing a novel thermoelectric element with a unique structure.

3. Step (a) above is, (a1) The upper part of the lower punch provided in the punch section is inserted into the inside of the mold section; (a2) A step in which the thermoelectric material powder is supplied to the upper surface of the lower punch; (a3) The spacer portion is positioned on top of the thermoelectric material powder supplied to the upper surface of the lower punch; (a4) The step of supplying the thermoelectric material powder into the mold portion; and, (a5) The lower part of the upper punch provided in the punch section is inserted into the interior of the mold section; A method for mass-producing a novel thermoelectric element with a new structure as described in claim 1.

4. Step (a) above is, (a1) The upper part of the lower punch provided in the punch section is inserted into the inside of the mold section; (a2) A step in which one of the many sheet portions is positioned on top of the lower punch; (a3) A step in which the thermoelectric material powder is supplied to the upper surface of any one of the sheet portions; (a4) The step of positioning the spacer portion on top of the thermoelectric material powder supplied to the upper surface of any one of the sheet portions; (a5) A step in which the thermoelectric material powder is supplied to the inside of the molded portion; (a6) A step in which one of the numerous sheet portions is positioned on top of the spacer portion; and, (a7) The lower part of the upper punch provided in the punch section is inserted into the interior of the mold section; A method for mass-producing a novel thermoelectric element with a new structure as described in claim 1.

5. In step (a4) above, The spacer portion has a rectangular parallelepiped shape that extends long in one direction. In step (a4) above, the thermoelectric material powder is supplied to the inside of the mold portion, thereby surrounding the spacer portion. A method for mass-producing a novel thermoelectric element with a new structure as described in claim 3.

6. In step (a4) above, The aforementioned spacer portion is Numerous horizontal spacers that extend horizontally and are arranged to be separated from each other vertically; and, Includes a pair of vertical spacers that extend long in the vertical direction and are formed at each end of the plurality of horizontal spacers; In step (a5), the thermoelectric material powder is supplied into the mold portion and surrounds the spacer portion while filling the numerous slits formed between the numerous horizontal spacers and the pair of vertical spacers. A method for mass-producing a novel thermoelectric element with a new structure as described in claim 4.

7. Step (a) above is, (a1) After the lowermost of the numerous spacer portions is placed on the upper part of the lower punch provided in the punch portion, the thermoelectric material powder is supplied into the interior of the lowermost spacer portion; (a2) After an n-layer spacer portion is placed on top of the spacer portion located at the lowest part, the step of supplying thermoelectric material powder into the interior of the n-layer spacer portion; and (a3) After the spacer portion located at the top of the n-layer spacer portion is positioned on top of the numerous spacer portions, the step of supplying thermoelectric material powder into the spacer portion located at the top is included; A method for mass-producing a novel thermoelectric element with a new structure as described in claim 2.

8. Step (a1) above is, (a11) A step in which the lowest of the numerous sheet portions is positioned on top of the lower punch; (a12) A step in which the thermoelectric material powder is supplied to the upper part of the sheet portion located at the lowest part; (a13) The lowermost spacer portion is positioned on top of the thermoelectric material powder supplied to the upper part of the lowermost sheet portion; (a14) A step in which the thermoelectric material powder is supplied to the upper part of the spacer portion located at the lowest part; (a15) A step in which one of the numerous sheet portions is positioned on top of the thermoelectric material powder supplied to the spacer portion located at the bottom; and, (a16) The step of positioning an n-layer support portion among a number of support portions on top of any one of the sheet portions; A method for mass-producing a novel thermoelectric element with a new structure as described in claim 7.

9. Step (a2) above is, (a21) A step in which an n-layer sheet portion is placed on top of the n-layer support portion among the numerous sheet portions; (a22) A step in which the thermoelectric material powder is supplied to the upper part of the n-layer sheet portion; (a23) A step in which an n-layer spacer portion is placed on top of the thermoelectric element powder supplied to the upper part of the n-layer sheet portion; and (a24) The step of supplying the thermoelectric material powder to the upper part of the n-layer spacer portion; Steps (a21) through (a24) are repeated until the previously set number of times reaches n (n = a natural number). A method for mass-producing a novel thermoelectric element with a new structure as described in claim 8.

10. Step (a3) ​​above is, (a31) A step in which one of the numerous sheet portions is positioned on top of the thermoelectric material powder supplied to the top of the n-layer spacer portion; (a32) The step of supplying the thermoelectric material powder to the upper part of the other sheet portion; (a33) The uppermost of the numerous spacer portions is positioned on top of the thermoelectric material powder supplied to the top of the other sheet portion; (a34) A step in which the thermoelectric material powder is supplied to the upper part of the spacer portion located at the uppermost position; (a35) The step of positioning the uppermost sheet portion among the numerous sheet portions on top of the thermoelectric material powder supplied to the uppermost spacer portion; and (a35) A step in which the upper punch provided in the punch section is positioned on the upper part of the sheet section located at the uppermost position; A method for mass-producing a novel thermoelectric element with a new structure as described in claim 9.

11. Between step (c) and step (d), The step of removing the numerous sintered bodies sintered inside the mold portion after the upper and lower punches provided in the punch portion have moved upward and downward and separated from the mold portion; further comprising: A method for mass-producing a novel thermoelectric element with a new structure as described in claim 2.

12. Between step (c) and step (d), The step of removing the sintered body that has been sintered inside the mold after the upper punch and the lower punch have moved to the upper and lower parts and separated from the mold; further comprising: A method for mass-producing a novel thermoelectric element according to claim 3 or 4.

13. Step (d) above is, (d1) A step of cutting both sides of the numerous sintered bodies in the longitudinal direction; (d2) A step of cutting the number of sintered bodies in the transverse direction while maintaining a predetermined interval in the vertical direction; (d3) A step of cutting the numerous sintered bodies in the vertical direction while maintaining a predetermined interval in the horizontal direction; and, (d4) The step of manufacturing the plurality of thermoelectric elements; A method for mass-producing a novel thermoelectric element with a new structure as described in claim 2.

14. Step (d) above is, (d1) A step of cutting the sintered body in the vertical direction while maintaining a predetermined interval in the horizontal direction; and, (d2) The step of manufacturing the plurality of thermoelectric elements; A method for mass-producing a novel thermoelectric element with a new structure as described in claim 3.

15. Step (d) above is, (d1) A step of cutting both sides of the sintered body in the longitudinal direction; (d2) A step of cutting the sintered body in the transverse direction while maintaining a predetermined interval in the vertical direction; (d3) A step of cutting the sintered body in the vertical direction while maintaining a predetermined interval in the horizontal direction; and, (d4) The step of manufacturing the plurality of thermoelectric elements; A method for mass-producing a novel thermoelectric element with a new structure as described in claim 4.

16. In a new structure thermoelectric element manufactured by a mass production method for a new structure thermoelectric element described in any one of claims 1, 3, or 4, A hexahedral spacer; and, A thermoelectric material is included that surrounds four of the six surfaces of the spacer, excluding the two surfaces that face each other; The two opposing surfaces of the spacer are exposed to the outside. A new thermoelectric element with the following characteristics.

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