Thermoelectric Conversion Element Shape Factor Optimization
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Solution Overview
Problem
The shape factor of thermoelectric conversion elements, which determines their thermoelectric characteristics, is challenging to achieve effectively in existing manufacturing methods, limiting the optimal ratio between height and cross-sectional area.
Innovation Solution
A method involving forming a thermoelectric film on a substrate, pressing it with a mold to create a pattern, and heating it to generate the thermoelectric conversion element, ensuring the shape factor is optimized by satisfying specific geometric conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing methods are used, then manufacturing simplicity is maintained, but the shape factor (ratio between height and cross-sectional area) cannot be optimized
Solution Approach 1:
The patent applies preliminary action by forming a patterned thermoelectric film on the substrate before final element formation. The mold presses the thermoelectric material into a predetermined pattern during the film formation stage, establishing the geometric configuration early in the manufacturing process. This preliminary patterning enables precise control of the shape factor while simplifying subsequent manufacturing steps.
2Manufacturing precision
If the thermoelectric film is pressed with a mold to form a pattern, then the shape factor is optimized, but the manufacturing process complexity increases
Solution Approach 1:
The patent merges multiple functions into the mold pressing step. The mold simultaneously performs patterning of the thermoelectric film, defines the geometric shape for optimal shape factor, and prepares the structure for subsequent heating and element formation. This consolidation of functions into a single operation achieves precise shape factor control without proportionally increasing manufacturing complexity.
3Reliability
If the pattern of thermoelectric film is heated to generate the thermoelectric conversion element, then the thermoelectric characteristics are improved, but energy consumption increases
Solution Approach 1:
The patent applies parameter changes by controlling the heating process to achieve specific crystal grain sizes and material properties. The heating temperature, duration, and atmosphere are optimized to transform the patterned film into a functional thermoelectric element with enhanced characteristics. This controlled parameter adjustment improves thermoelectric performance while minimizing unnecessary energy consumption.
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 allows for the efficient manufacturing of thermoelectric conversion elements with an appropriate shape factor, enhancing their thermoelectric characteristics and mechanical properties, while reducing material waste and improving crystal grain size.
Implementation Method 1
A thermoelectric conversion element that generates electric power by utilizing the Seebeck effect is known.
Data Source
AI summary
A method for manufacturing a thermoelectric conversion element includes forming a thermoelectric film containing a thermoelectric material on a surface of a substrate, pressing the thermoelectric film with a mold to form a pattern of the thermoelectric film on the surface of the substrate, and heating the pattern of the thermoelectric film formed on the surface of the substrate to generate the thermoelectric conversion element.