Thermoelectric Material Optical Sintering Flexible Substrates
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Solution Overview
Problem
Conventional thermoelectric modules face challenges in being applied to curved substrates due to thermal deformation during high-temperature sintering, and existing low-temperature sintering methods are inefficient or unsuitable for mass production, especially when trying to achieve flexible and high-performance thermoelectric materials with good adhesion to substrates.
Innovation Solution
A thermoelectric material is developed using optical sintering with xenon white light, where the lower part has a high content of carbon atoms for improved adhesion and the upper part has a lower carbon content for enhanced thermoelectric performance, allowing for flexible substrate application without thermal deformation, and a thermoelectric module is formed using this material with a carbon-based binder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-temperature and/or high-pressure sintering is used to manufacture thermoelectric material, then thermoelectric performance is improved, but thermal deformation of flexible substrate occurs and adhesion integrity deteriorates
Solution Approach 1:
The sintering process is segmented into two distinct stages: a first sintering stage at lower temperature (room temperature to 200°C) to form a green body with adequate adhesion, and a second sintering stage at higher temperature (200°C to 600°C) to enhance thermoelectric performance. This segmentation allows the flexible substrate to withstand the overall process without thermal deformation while achieving high-performance thermoelectric material through the second stage sintering.
2Reliability
If conventional sintering methods are used, then thermoelectric material is formed, but mass production efficiency is low and process complexity increases
Solution Approach 1:
The conventional mechanical and thermal field-based sintering methods are replaced with an electromagnetic field-based sintering approach. By applying an alternating current to the electrode, electromagnetic induction generates eddy currents within the thermoelectric material particles, producing rapid localized heating that achieves dense sintering in seconds. This substitution enables mass production with high efficiency while maintaining material density.
3Object-affected harmful factors
If laser sintering is used for low-temperature sintering, then substrate thermal deformation is prevented, but mass production suitability decreases due to selective processing requirements
Solution Approach 1:
The electromagnetic induction sintering method serves multiple functions simultaneously: it provides low-temperature sintering to prevent substrate thermal deformation, enables rapid processing for mass production, and achieves uniform densification across the entire workpiece without selective processing. The alternating current applied to the electrode creates a uniform electromagnetic field that acts on all thermoelectric material particles at once, making the process universally applicable to various shapes and sizes suitable for mass production.
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 enables the production of flexible thermoelectric modules with improved thermoelectric performance and adhesion to substrates, achieved through optical sintering at room temperature, which is efficient and suitable for mass production, overcoming the limitations of conventional high-temperature sintering methods.
Implementation Method 1
A thermoelectric module uses a Seebeck effect that generates the thermoelectric power by a temperature difference between opposite sides
Implementation Method 2
there is provided a thermoelectric material manufactured by an optical sintering using xenon white light instead of a high-temperature and/or high-pressure sintering
Data Source
AI summary
A thermoelectric material includes a lower part from a bottom surface of the thermoelectric material to a point of 30% of an average thickness of the thermoelectric material and having an average content of carbon atoms of 40 at% or more in the thermoelectric material, and an upper part corresponding to a remaining 70% of the average thickness of the thermoelectric material and having an average content of carbon atoms of 20 at% or less in the thermoelectric material.