Thermoelectric Element Electrode Sintering for Dimension Variation
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Solution Overview
Problem
Dimension variations in thermoelectric conversion materials lead to bonding issues between electrodes and thermoelectric conversion materials, causing peeling, defective interfaces, and uneven thermal and electrical resistance, which affect the thermoelectric characteristics and load balance of the conversion element.
Innovation Solution
A manufacturing method where electrodes are formed by sintering metal powder at the end portions of thermoelectric conversion members, coating exposed ends to absorb dimension variations, and bonding them in a way that maintains alignment and contact, preventing additional processing and ensuring stable bonding strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If dimension variation of thermoelectric conversion material is reduced by additional processing (grinding or polishing), then bonding quality between electrode and thermoelectric conversion material is improved, but manufacturing cost is increased
Solution Approach 1:
The invention applies preliminary action by forming a metal powder coating layer on the thermoelectric conversion material before the bonding process. This coating layer is applied in advance to compensate for dimension variations, eliminating the need for subsequent grinding or polishing operations. The coating is formed by introducing metal powder onto the thermoelectric conversion material surface before electrode bonding, thereby pre-compensating for dimensional inconsistencies.
Solution Approach 2:
The invention applies parameter changes by transforming the surface characteristics of the thermoelectric conversion material through metal powder coating. Instead of mechanically removing material to achieve dimensional precision, the method changes the surface parameter by adding a metal powder layer that compensates for height variations. This parameter change approach converts a dimensional problem into a surface coating problem, reducing manufacturing complexity and cost.
2Ease of manufacture
If electrode is bonded to thermoelectric conversion material with dimension variation, then manufacturing process is simplified, but bonding interface quality deteriorates (peeling, defective interface, uneven resistance)
Solution Approach 1:
The invention applies the intermediary principle by introducing a metal powder coating layer as a mediator between the electrode and the thermoelectric conversion material. This intermediate layer compensates for dimension variations and ensures uniform contact across the bonding interface. The metal powder coating acts as a buffer that accommodates height differences, preventing peeling and defective bonding while maintaining electrical and thermal contact uniformity.
Solution Approach 2:
The invention applies preliminary action by preparing the metal powder coating layer on the thermoelectric conversion material surface before the electrode bonding process. This preliminary coating ensures that when the electrode is pressed against the material, the contact interface is already optimized for uniform pressure distribution and electrical contact, preventing bonding defects without requiring complex bonding process control.
3Manufacturing precision
If additional processing (grinding or polishing) is applied to thermoelectric conversion material, then dimension variation is reduced, but manufacturing time and complexity are increased
Solution Approach 1:
The invention applies discarding and recovering by eliminating the need for material removal processes (grinding or polishing). Instead of discarding material to achieve dimensional precision, the method recovers efficiency by using a additive approach (metal powder coating) that achieves the same dimensional compensation goal without the complexity of precision machining operations.
Solution Approach 2:
The invention applies preliminary action by forming the metal powder coating layer before bonding, thereby pre-compensating for dimension variations. This preliminary action eliminates the need for subsequent precision processing steps, reducing overall manufacturing complexity while achieving the required dimensional uniformity for quality bonding.
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 method prevents deterioration of thermoelectric properties and load balance due to dimension variations, enhances bonding strength, and reduces manufacturing costs by eliminating the need for additional processing of thermoelectric conversion materials.
Implementation Method 1
an electrode is formed at at least one end portion of at least one thermoelectric conversion member by sintering metal powder
Implementation Method 2
Joule heat is generated by flowing the electric current, heating is performed only in a narrow range, so that sintering time is shortened and further temperature unevenness can be reduced
Implementation Method 3
A thermoelectric conversion element can convert thermal energy into electrical energy by the Seebeck effect
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
To provide a manufacturing method of a thermoelectric conversion element, including: a holding step of holding thermoelectric conversion members (2, 3) while exposing at least one side end portions of at least one of the thermoelectric conversion members; a coating step of coating the exposed end portions of the thermoelectric conversion member with metal powder (13); and an electrode forming step of forming an electrode (4a) at the end portions of the thermoelectric conversion member by sintering the metal powder.