Thermoelectric Module Diffusion Layer Composition for Heat-Resistant Bonding
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Solution Overview
Problem
The existing thermoelectric conversion modules have inadequate connecting properties between the thermoelectric conversion layer and the diffusion prevention layer, and insufficient heat resistance.
Innovation Solution
A thermoelectric conversion module member is designed with a thermoelectric conversion layer containing a silicon or tellurium element and a diffusion prevention layer made of a metal with the same thermoelectric conversion material, where the thermoelectric conversion material in the diffusion prevention layer is 10 to 50 parts by weight per 100 parts of metal, forming a sea-island phase separation structure for improved connectivity and heat resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a diffusion prevention layer containing only metal such as Ni is used, then substance diffusion between the thermoelectric conversion layer and electrode is prevented, but connecting property between the thermoelectric conversion layer and diffusion prevention layer is insufficient and heat resistance is poor
Solution Approach 1:
The diffusion prevention layer is constructed as a composite material containing both metal particles (Ni, Cu, or their alloys) and thermoelectric conversion material particles (Bi2Te3-based or other thermoelectric materials). This composite structure provides both diffusion prevention capability and improved connecting property and heat resistance through the dual-component formulation.
Solution Approach 2:
The invention specifies precise compositional parameters for the diffusion prevention layer: metal content of 50-95 mass% and thermoelectric conversion material content of 5-50 mass%. Additionally, the particle size ratio between metal particles and thermoelectric conversion material particles is controlled (0.5-2.0 times larger for metal particles). These parameter optimizations resolve the contradiction between connecting property and heat resistance.
2Ease of manufacture
If the diffusion prevention layer contains only metal, then manufacturing is simplified, but the connecting property and heat resistance are insufficient
Solution Approach 1:
Rather than using pure metal which is easier to manufacture, the invention employs a composite material system combining metal particles with thermoelectric conversion material particles. This approach maintains manufacturing feasibility through simple mixing and sintering processes while dramatically improving heat resistance and connecting properties.
Solution Approach 2:
The invention optimizes manufacturing parameters including the mass ratio of metal to thermoelectric material (50:50 to 95:5), particle size ratios (0.5-2.0 times), and sintering conditions. These parameter specifications enable reliable production of the composite diffusion prevention layer with enhanced performance.
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 solution enhances the connecting property and heat resistance of the thermoelectric conversion module member, leading to improved thermal efficiency and durability.
Implementation Method 1
converting heat into electric power by utilizing the Seebeck effect in which electromotive force is generated in response to a temperature difference
Data Source
AI summary
To provide a thermoelectric conversion module member which has a high connecting property between a thermoelectric conversion layer and a diffusion prevention layer and is also excellent in heat resistance.A thermoelectric conversion module member comprising a thermoelectric conversion layer and a diffusion prevention layer in contact with the above-described thermoelectric conversion layer, wherein the above-described thermoelectric conversion layer is a layer containing a thermoelectric conversion material having a silicon element or a tellurium element, the above-described diffusion prevention layer is a layer containing a metal and the same thermoelectric conversion material as that contained in the above-described thermoelectric conversion layer, and the amount of the above-described thermoelectric conversion material in the above-described diffusion prevention layer is 10 to 50 parts by weight with respect to 100 parts by weight of the above-described metal.