Thermoelectric Module Interfacial Coating for Thermal Stress Mitigation

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Solution Overview

Problem

Thermoelectric modules face mechanical degradation due to thermal stress from temperature differences, leading to reduced thermal and mechanical stability, particularly at the interface between thermoelectric materials and electrodes.

Innovation Solution

A composite coating layer comprising a transition layer and a diffusion prevention layer is introduced between the thermoelectric material and the electrode, with the transition layer made of materials like Co, Sn, CoTe, or CoTe2, and the diffusion prevention layer made of metals such as Ti or Pt, to mitigate thermal stress and improve interfacial stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If a thermoelectric module operates based on temperature difference, then power generation or cooling function is achieved, but thermal stress from temperature differences causes mechanical degradation and reduces thermal and mechanical stability

Engineering Contradiction:

Improvepower generation capabilityVSAvoidthermal and mechanical stability

Core Design Contradiction:

PowerVSReliability

Solution Approach 1:

A diffusion prevention layer is introduced as an intermediary between the thermoelectric material and the electrode. This intermediate layer acts as a buffer that prevents direct thermal stress transmission and material diffusion, thereby maintaining both the power generation capability and improving thermal-mechanical stability under temperature differences.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The interface structure is designed as a composite system consisting of the thermoelectric material layer, diffusion prevention layer, and electrode. This composite structure combines materials with different thermal and mechanical properties to simultaneously achieve power generation function and resistance to thermal stress-induced mechanical degradation.

Inventive Principle:

Principle #40Composite materials

2Device complexity

If thermoelectric material directly contacts electrode, then simple structure is achieved, but interfacial characteristics deteriorate due to thermal stress and material diffusion

Engineering Contradiction:

Improveinterface structure complexityVSAvoidinterfacial stability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If diffusion prevention layer is added between thermoelectric material and electrode, then interfacial stability is improved, but device complexity increases

Engineering Contradiction:

Improveinterfacial stabilityVSAvoidlayer structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The interface region is segmented into distinct functional layers: a thermoelectric material layer, a diffusion prevention layer, and an electrode. This segmentation allows each layer to be optimized for its specific function while maintaining overall system performance and stability.

Inventive Principle:

Principle #1Segmentation

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

The composite coating layer enhances thermal and mechanical stability, reduces interfacial resistance, and improves the durability and performance of thermoelectric modules by minimizing thermal impact and mechanical damage from thermal expansion differences.

Implementation Method 1

a diffusion prevention layer on the transition layer

Methodology Applied

Scientific EffectDiffusion prevention: Diffusion Barrier

Implementation Method 2

the transition layer may include at least one of Co, Sn, CoTe, CoTe2, or SnTe

Methodology Applied

Scientific EffectThermal stress mitigation: Thermal Expansion

Data Source

PatentUS10326068B2Thermoelectric device, thermoelectric module including the thermoelectric device, thermoelectric apparatus including the thermoelectric module, and method of manufacturing the same

Publication Date: 2019.06.18 SAMSUNG ELECTRONICS CO LTD

AI summary

A thermoelectric device including: a thermoelectric material layer comprising a thermoelectric material; a transition layer on the thermoelectric material; and a diffusion prevention layer on the transition layer, wherein the thermoelectric material comprises a compound of Formula 1:(A1-aA′a)4-x(B1-bB′b)3-y-zCz Formula 1wherein A and A′ are different from each other, A is a Group 13 element, and A′ is at least one element of a Group 13 element, a Group 14 element, a rare-earth element, or a transition metal, B and B′ are different from each other, B is a Group 16 element, and B′ is at least one element of a Group 14 element, a Group 15 element, or a Group 16 element, C is at least one halogen atom, a complies with the inequality 0≤a<1, b complies with the inequality 0≤b<1, x complies with the inequality −1<x<1, y complies with the inequality −1<y<1, and z complies with 0≤z<0.5.