Thermoelectric Module Bonding Apparatus Preventing Oxidation
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Solution Overview
Problem
Conventional thermoelectric module manufacturing processes result in oxidation of thermoelectric pellets during bonding, degrading wettability and conductivity, and require multiple bonding processes, leading to reduced productivity and performance.
Innovation Solution
An apparatus that uses a fixing unit with a first die for heating the first adhesive layer between thermoelectric pellets and first electrodes, and a second die for heating the second adhesive layer between pellets and second electrodes, allowing for a single bonding process while preventing oxidation of the thermoelectric pellets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two separate bonding processes are used for first and second electrodes, then each electrode can be bonded with appropriate adhesive temperature, but the thermoelectric pellet surface becomes oxidized and wettability and conductivity are degraded
Solution Approach 1:
The patent combines two separate bonding processes into a single simultaneous bonding operation. Both first and second electrodes are bonded to the thermoelectric pellet at the same time using a unified bonding process, which prevents oxidation by eliminating the intermediate state where the pellet surface is exposed to high-temperature atmosphere without protective coating.
Solution Approach 2:
The patent applies preliminary protective action by coating the thermoelectric pellet surface with a protective layer before bonding. This protective coating prevents oxidation during the bonding process while allowing the bonding to proceed effectively, thus maintaining both reliability and preventing harmful oxidation.
2Reliability
If two bonding processes are required for electrodes, then appropriate adhesives can be used for different temperatures, but productivity is lowered
Solution Approach 1:
The patent merges two sequential bonding operations into one simultaneous bonding step. By using a unified bonding apparatus that can apply both adhesives and heat/pressure conditions for both electrode-bonding operations concurrently, the manufacturing cycle time is reduced while maintaining the reliability of each specific bonding interface.
Solution Approach 2:
The bonding apparatus is designed with multi-functionality to handle both first and second electrode bonding operations simultaneously. The system can apply different adhesive types and control different temperature zones while performing a single integrated bonding process, thus improving productivity without sacrificing bonding performance.
3Strength
If high-temperature atmosphere is used for first electrode bonding, then first adhesive bonds properly, but second electrode bonding is adversely affected by oxidation
Solution Approach 1:
The patent applies a protective coating to the thermoelectric pellet surface before the bonding process. This preliminary protective action allows the first electrode bonding to proceed at high temperature for strong adhesive bonding, while the protective coating simultaneously prevents oxidation that would otherwise degrade the surface quality needed for second electrode bonding.
Solution Approach 2:
The patent creates an inert or protective atmosphere environment during bonding, either through protective coatings on the pellet surface or by controlling the atmospheric composition in the bonding chamber. This inert environment prevents oxidation reactions even when high temperatures are applied for strong adhesive bonding of the first electrode.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances the bonding process, preventing oxidation, improving the durability and performance of thermoelectric modules, and increasing productivity by simplifying the bonding process to a single step.
Implementation Method 1
a first heating member that heats a first adhesive layer, which is interposed between the surfaces of the thermoelectric pellets and the first electrodes
Implementation Method 2
a second heating member that heats a second adhesive layer, which is interposed between the opposite surfaces of the thermoelectric pellets and the second electrodes
Implementation Method 3
the surface of the thermoelectric pellet, to which the second electrode is bonded, is oxidized due to the higher-temperature atmosphere made when the first electrode is bonded to the thermoelectric pellet
Data Source
AI summary
An apparatus for manufacturing a thermoelectric module is provided. The thermoelectric module includes thermoelectric pellets, first electrodes, second electrodes, and an insulating substrate. The apparatus includes a fixing tray to which the thermoelectric module is fixed, a first die including a first heating member configured to heat a first adhesive layer, which is interposed between the thermoelectric pellets and the first electrodes. The fixing tray is mounted on the first die such that the insulating substrate faces the first heating member. A second die includes a second heating member configured to heat a second adhesive layer, which is interposed between the thermoelectric pellets and the second electrodes, the second die facing the second electrodes. A transfer unit is configured to transfer at least one of the first die and the second die to adjust a distance between the first die and the second die.