Thermoelectric Module Joining With Controlled Nanoparticle Paste Deposition
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Solution Overview
Problem
The application of metal nanoparticle pastes in thermoelectric conversion modules is challenging due to their characteristic fluid properties, leading to difficulties in controlling the application amount, which results in disconnection or short circuits and lowers the output density of the module.
Innovation Solution
A method involving the use of metal nanoparticles with a controlled application process using a mechanical dispenser, applying the paste in a non-contact manner to both sides of the thermoelectric conversion elements, followed by sintering to form joining members, ensuring a stable and controlled joint area between conductive members and elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If metal nanoparticle paste is applied using conventional printing or metal mask methods, then the application process is simple, but the application amount cannot be controlled precisely leading to disconnection or short circuit
Solution Approach 1:
The patent introduces a mechanical dispenser as an intermediary device between the paste container and the thermoelectric conversion element. This dispenser precisely controls the application amount of metal nanoparticle paste by mechanically dispensing it in a non-contact manner, thereby achieving precise application amount control without direct contact with the element surface.
Solution Approach 2:
The patent replaces conventional printing methods and metal mask systems with a mechanical dispenser system. This substitution eliminates the need for complex masking processes and enables precise control of paste application amount through mechanical dispensing mechanisms, resolving the contradiction between precision and complexity.
2Temperature
If metal nanoparticles with small particle size are used to reduce sintering temperature, then the sintering temperature is below the melting point of the metal, but the characteristic fluid property makes it difficult to control the application amount
Solution Approach 1:
The mechanical dispenser serves as an intermediary that bridges the gap between the fluid metal nanoparticle paste and the target surface. It controls the dispensing process to achieve precise application amount control despite the paste's characteristic fluid properties, allowing the use of fine metal nanoparticles without compromising application precision.
Solution Approach 2:
The patent changes the application method parameters by using a mechanical dispenser that can precisely control the volume and placement of paste. This parameter change in the application process enables controlled application of metal nanoparticle paste with small particle sizes, maintaining both low sintering temperature and precise application control.
3Power
If the application amount of paste varies, then the output density of the thermoelectric conversion module decreases, but achieving high output density requires precise control of the application amount
Solution Approach 1:
The mechanical dispenser acts as a precision intermediary that ensures consistent and controlled application of metal nanoparticle paste. This intermediary device eliminates variation in application amount, thereby enabling the thermoelectric conversion module to achieve high output density by ensuring proper electrical connection without disconnection or short circuit.
Solution Approach 2:
The patent implements a controlled dispensing process where the mechanical dispenser applies paste in a regulated manner. This feedback-controlled application ensures that the correct amount of paste is applied consistently, which is critical for achieving high output density by preventing both disconnection and short circuit conditions.
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 enables the production of thermoelectric conversion modules with high output density by maintaining dispersion and controlled application, reducing the risk of short circuits and improving heat transfer efficiency.
Implementation Method 1
a paste containing metal nanoparticles is applied by the mechanical dispenser in a non-contact manner onto both sides of the thermoelectric conversion elements, followed by sintering to form joining members
Implementation Method 2
the present invention relates to a method for manufacturing a thermoelectric conversion module that directly converts thermal energy into electrical energy by using a heat source of waste heat
Data Source
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Figure 2(a)~2(f)
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AI summary
In the case of manufacturing a thermoelectric conversion module using a paste including metal nanoparticles, it is difficult to apply the paste onto a thermoelectric conversion element in a controlled amount due to effects of specific fluid properties such as thixotropy, and it is difficult to obtain high output density as a thermoelectric conversion module due to an open circuit, a short circuit, or the like. This method is for manufacturing a thermoelectric conversion module in which a first conductive member, a thermoelectric conversion element, a second conductive member are joined by joining members, the method comprising: a step for, after applying on the first conductive member a first paste including metal particles, disposing the thermoelectric conversion element on the first paste, and compressing and spreading the first paste; a step for disposing the second conductive member, after applying a second paste including metal particles in a controlled amount, on the thermoelectric conversion element, and compressing and spreading the second paste; and a step for sintering the first and the second pastes to obtain joining members.