Technical Field
[0001] The present invention relates to a thermoelectric conversion module which generates
electricity by thermoelectric conversion based on the Seebeck effect.
Background Art
[0002] The thermoelectric conversion module is a module comprising thermoelectric conversion
elements capable of converting thermal energy into electrical energy through the Seebeck
effect. Thermoelectric conversion modules and thermoelectric conversion elements for
forming them are attracting attention as environmentally-friendly energy-saving technology,
because they can convert waste heat, expelled from industrial or consumer processes
or moving vehicles, into available electricity by making use of this energy conversion
property.
[0003] Such thermoelectric conversion modules are commonly formed by connecting thermoelectric
conversion elements (p-type and n-type semiconductor elements) by electrodes. A thermoelectric
conversion module of this type is disclosed in Patent Document 1, for example. The
thermoelectric conversion module in Patent Document 1 comprises a pair of substrates,
a plurality of thermoelectric conversion elements which are electrically connected
to first electrodes arranged on one of the substrates at their first ends, and to
second electrodes arranged on the other substrate at their opposite, second ends,
and connectors each electrically connecting the first electrode connected to a thermoelectric
conversion element to the second electrode connected to an adjacent thermoelectric
conversion element. Furthermore,
US 2010/0059096 A1 discloses a thermoelectric module which has a stress-mitigation unit including a
slit and an incision that relieves stress produced by temperature difference of both
ends of a semiconductor element.
Prior Art Document
Patent Document
[0004] Patent Document 1: Japanese Unexamined Patent Application Publication No.
2013-115359
Summary of the Invention
Problems to be solved by the Invention
[0005] However, when the thermoelectric conversion module configured as disclosed in Patent
Document 1 is applied to a heating source such as an exhaust system of an engine,
if the temperature of the thermoelectric conversion elements increases too greatly
due to the module's location near the engine or the amount of heat increased, for
example by an increase in the amount of exhaust gas from the engine, the electricity
generation performance of the thermoelectric conversion elements decreases.
[0006] The present invention has been made in view of the above problem. An object of the
present invention is to provide a thermoelectric conversion module which can maintain
high electricity generation performance even when applied to a relatively high-temperature
heat source.
Means for Solving the Problems
[0007] In order to achieve the above object, the thermoelectric conversion module applied
to a heating source according to the present invention comprises a plurality of thermoelectric
conversion elements arranged adjacent to each other, first electrodes located away
from the heating source and joined to first ends of the thermoelectric conversion
elements to electrically connect the first ends of adjacent thermoelectric conversion
elements, second electrodes located nearer to the heating source and joined to opposite,
second ends of the thermoelectric conversion elements to electrically connect the
second ends of adjacent thermoelectric conversion elements, wherein the thermoelectric
conversion elements each comprise a first structural portion joined to the first electrode
and a second structural portion joined to the second electrode, the second electrode
being smaller in volume than the first electrode, wherein the thermoelectric elements
are diffusion-bonded to the second electrodes.
Advantageous Effects of the Invention
[0008] The thermoelectric conversion module according to present invention can maintain
high electricity generation performance even when applied to a relatively high-temperature
heat source.
Brief Description of the Drawings
[0009]
FIG. 1 is a perspective view of a thermoelectric conversion module according to an
embodiment.
FIG. 2 is a top view of the thermoelectric conversion module according to the embodiment.
FIG. 3 is a cross-sectional view of the thermoelectric conversion module along line
III-III in FIG. 2.
FIG. 4 is a diagram schematically showing the structure of a thermoelectric conversion
element for use in the thermoelectric conversion module according to the present embodiment.
FIG. 5 is a side view of an electrode for use in the thermoelectric conversion module
according to the present embodiment.
FIG. 6 is a diagram schematically showing the structure of a thermoelectric conversion
element according to a variant.
FIG. 7 is a diagram schematically showing the structure of a thermoelectric conversion
element according to another variant.
Mode of Carrying out the Invention
[0010] With reference to the accompanying drawings, how to carry out the thermoelectric
conversion module according to the present invention will be described in detail based
on an embodiment. The drawings used in explanation of the embodiment show the thermoelectric
conversion module according to the present invention and its components, schematically;
in order to help understanding, the drawings may contain partial emphasis, enlargement,
contraction, omission or the like, and thus, may not necessarily show the components
on an accurate scale and in an accurate shape. Further, numerical values mentioned
in connection with the embodiment are all given by way of example; they may be varied
as necessary.
〈Embodiment〉
(Configuration of a thermoelectric conversion module)
[0011] With reference to FIGS. 1 to 4, the configuration of a thermoelectric conversion
module 1 according to an embodiment will be described. FIG. 1 is a perspective view
of the thermoelectric conversion module 1 according to the embodiment. FIG. 2 is a
top view of the thermoelectric conversion module 1 according to the embodiment. FIG.
3 is a cross-sectional view of the thermoelectric conversion module along line III-III
in FIG. 2. FIG. 4 is a diagram schematically showing the structure of a thermoelectric
conversion element for forming the thermoelectric conversion module 1. In FIG. 1,
one direction is referred to as X direction, and directions perpendicular to X direction
are referred to as Y direction and Z direction. Specifically, the direction parallel
to the height of the thermoelectric conversion module 1 is referred to as Z direction.
[0012] As seen from FIGS. 1 to 3, the thermoelectric conversion module 1 according to the
present embodiment comprises first and second thermoelectric conversion elements 2a,
2b arranged adjacent to each other, and first and second electrodes 3a, 3b joined
to the opposite ends of the first and second thermoelectric conversion elements 2a,
2b. The thermoelectric conversion module 1 according to the present embodiment further
comprises connecting electrodes 3c which connect the first electrodes 3a located at
each X-way end of the thermoelectric conversion module 1 to each other, and extraction
electrodes 3d which function as external connection electrodes of the thermoelectric
conversion module 1. The thermoelectric conversion module 1 according to the present
embodiment further comprises a first covering layer 4 provided to cover the first
electrodes 3a, a second covering layer 5 provided to cover the first and second thermoelectric
conversion elements 2a, 2b and the connecting electrodes 3c, and a support substrate
6 provided to support the second electrodes 3b. The thermoelectric conversion module
1 is arranged with the support substrate 6 side in contact with a heating source such
as an automotive engine.
[0013] When mentioning the individual connecting electrodes 3c, they will be referred to
as connecting electrode 3c
1, connecting electrode 3c
2, connecting electrode 3c
3 and connecting electrode 3c
4, and when mentioning the individual extraction electrodes 3d, they will be referred
to as extraction electrode 3d
1 and extraction electrode 3d
2.
[0014] In the present embodiment, the first thermoelectric conversion elements 2a are made
of an n-type semiconductor material, and the second thermoelectric conversion elements
2b are made of a p-type semiconductor material. The first and second thermoelectric
conversion elements 2a, 2b are arranged alternately in a matrix (eight in X direction,
five in Y direction, forty in all), where adjacent first and second thermoelectric
conversion elements 2a, 2b are electrically connected by first and second electrodes
3a, 3b.
[0015] In the present embodiment, the first thermoelectric conversion element 2a as well
as the second thermoelectric conversion element 2b has a shape consisting of two cylinders
of different diameter joined together, as shown in FIGS. 3 and 4. More specifically,
as shown in FIG. 4, the first thermoelectric conversion element 2a as well as the
second thermoelectric conversion element 2b consists of a first cylindrical portion
(first structural portion) 11 with a large diameter, or outer measurement (5mm in
diameter, for example) adjacent to the first electrode 3a and a second cylindrical
portion (second structural portion) 12 with a small diameter (3mm in diameter, for
example) adjacent to the second electrode 3b. In other words, each thermoelectric
conversion element consists of a first cylindrical portion 11 joined to the first
electrode 3a and a second cylindrical portion 12 smaller in volume than the first
cylindrical portion 11 and joined to the second electrode 3b, and thus, has a stepped
outer shape. By providing a difference in volume between the portions constituting
each thermoelectric conversion element, conduction of heat from the heating source
is controlled. The control of conduction of heat will be described in detail when
explaining a test result.
[0016] The first electrode 3a and the second electrode 3b are of the same shape (plate-like
shape) and made of copper, for example. The first electrodes 3a are arranged such
that five are arranged in a row in X direction and five are arranged in a row in Y
direction (thus, twenty-five in all). The first electrodes 3a located at the X-way
ends are each joined to a first thermoelectric conversion element 2a or a second thermoelectric
conversion element 2b, at an end, and joined to a connecting electrode 3c or an extraction
electrode 3d, at the opposite end. Meanwhile, the second electrodes 3b are arranged
such that four are arranged in a row in X direction and five are arranged in a row
in Y direction (thus, twenty in all). The second electrodes 3b are each joined to
a first thermoelectric conversion element 2a, at an end, and joined to a second thermoelectric
conversion element 2b, at the opposite end. As seen from FIGS. 1 and 3, the first
and second thermoelectric conversion elements 2a, 2b are sandwiched between the first
electrodes 3a and the second electrodes 3b in Z direction.
[0017] As a result of this arrangement of the first and second thermoelectric conversion
elements 2a, 2b and the first and second electrodes 3a, 3b, the first and second thermoelectric
conversion elements 2a, 2b are connected in series. Particularly in the present embodiment,
four first thermoelectric conversion elements 2a, four second thermoelectric conversion
elements 2b, five first electrodes 3a and four second electrodes 3b arranged in a
X-way row form a series circuit element 13. Accordingly, the thermoelectric conversion
module 1 contains five series circuit elements 13 in all. Series circuit elements
13 adjacent to each other in Y direction are connected by a connecting electrode 3c
at an end. When mentioning the individual series circuit elements 13, they will be
referred to as series circuit element 13a, series circuit element 13b, series circuit
element 13c, series circuit element 13d and series circuit element 13e.
[0018] The first electrode 3a as well as the second electrode 3b is not limited to a copper
plate; they may be made of another electrically-conductive material (metal such as
aluminum, for example). The number and shape of the first and second electrodes 3a,
3b are not limited to the above but may be changed appropriately depending on the
first and second thermoelectric conversion elements 2a, 2b (in other words, the magnitude
of electromotive force). Further, the first and second electrodes 3a, 3b may be arranged
to connect the first and second thermoelectric conversion elements 2a, 2b in parallel.
[0019] The connecting electrode 3c and the extraction electrode 3d are identical in structure.
Specifically, as shown in FIG. 5, they are each composed of a metal mesh 21 and two
metal plates 22 fixed to the metal mesh 21 at opposite ends. The connecting electrode
3c and the extraction electrode 3d, which include a metal mesh 21 with high flexibility,
have flexibility. The ratio of openings and the size of the opening in the metal mesh
21 may be selected appropriately to ensure that the connecting electrode 3c and the
extraction electrode 3d have high flexibility.
[0020] Although in the present embodiment, the metal mesh 21 and the metal plate 22 are
made of copper, they are not limited to copper but may be made of another metal. Particularly,
materials that can provide high electrical conductivity while ensuring high flexibility
of the connecting electrode 3c and the extraction electrode 3d are desirable. The
connecting electrode 3c and the extraction electrode 3d do not necessarily need to
contain a metal mesh 21 if they can have high flexibility; they may be formed using
a metallic material having a structure other than mesh.
[0021] As shown in FIG. 2, to a series circuit element 13a with a -Y-side extraction electrode
3d
1 joined at an end, a connecting electrode 3c
1 is joined at the opposite (+X-side) end, and the connecting electrode 3c
1 connects the series circuit element 13a to a +Y-side adjacent series circuit element
13b. To the series circuit element 13b, a connecting electrode 3c
2 is joined at a (-X-side) end opposite to the end connected to the series circuit
element 13a, and the connecting electrode 3c
2 connects the series circuit element 13b to a +Y-side adjacent series circuit element
13c. In like manner, the series circuit element 13c is connected to a series circuit
element 3d at a +X-side end by a connecting electrode 3c
3, and the series circuit element 13d is connected to a series circuit element 13e
at a -X-side end by a connecting electrode 3c
4. To the series circuit element 13e, an extraction electrode 3d
2 is joined at a +X-side end.
[0022] In the thermoelectric conversion module 1, the series circuit elements 13 connected
to each other by the connecting electrodes 3c in this manner form a zigzag series
circuit. The series circuit is provided with the extraction electrodes 3d for external
connection, at the opposite ends, which enable electricity generated by the thermoelectric
conversion module 1 to be extracted externally. To form the zigzag series circuit,
the first and second thermoelectric elements 2a, 2b forming the series circuit elements
13b, 13d alternate in reverse order, as compared with those forming the series circuit
elements 13a, 13c, 13e.
[0023] In the present embodiment in which the connecting electrodes 3c and extraction electrodes
3d having flexibility are joined at the ends of the series circuit elements 13, the
connecting electrodes 3c and extraction electrodes 3d do not separate from the first
electrodes 3a even when an increase in temperature of the thermoelectric conversion
module 1 brings about stress concentration. Further, when installed in a vehicle,
the thermoelectric conversion module 1 configured as described above can prevent electrode
separation due to vibration of the engine.
[0024] As seen from FIGS. 1 and 3, the first covering layer 4 covers the surfaces of the
first electrodes 3a in a manner that the first electrodes 3a are buried therein. The
first covering layer 4 is made of an insulating resin mixed with a metallic material
functioning as a thermally-conductive material, such as aluminum, copper or aluminum
nitride. The first covering layer 4 made of such mixture has a relatively high thermal
conductivity and provides good electrical insulation around the first electrodes 3a.
[0025] As seen from FIGS. 1 to 3, the second covering layer 5 covers the first and second
thermoelectric conversion elements 2a, 2b, the second electrodes 3b and the connecting
electrodes 3c in a manner that the first and second thermoelectric conversion elements
2a, 2b, the second electrodes 3b and the connecting electrodes 3c are buried therein.
The second covering layer 5 is made of an insulating resin mixed with a heat-insulating
material. Heat-insulating materials usable for the second covering layer 5 include
fibrous heat-insulating materials such as glass wool, and foam heat-insulating materials
such as polystyrene foam.
[0026] The second covering layer 5 made of such mixture is lower in thermal conductivity
than the first covering layer 5 and has a function of suppressing dissipation of heat
from the first and second thermoelectric conversion elements 2a, 2b, the second electrodes
3b and the connecting electrodes 3c. Accordingly, the second covering layer 5 helps
increase a temperature difference between the first electrodes 3a and the second electrodes
3b and keeps the temperature difference constant, thereby enabling greater electromotive
force to be produced. The second covering layer 5 also provides good electrical insulation
around the first and second thermoelectric conversion elements 2a, 2b, the second
electrodes 3b and the connecting electrodes 3c.
[0027] Further, the second covering layer 5 holds the first and second thermoelectric conversion
elements 2a, 2b, the second electrodes 3b and the connecting electrodes 3c relatively
firmly, leading to an increased strength of the thermoelectric conversion module 1.
Further, the first and second thermoelectric conversion elements 2a, 2b are completely
covered, and thus, prevented from getting broken, tainted or something, which suppresses
a decrease in thermoelectric conversion efficiency and reliability of the thermoelectric
conversion module 1. Further, none of the joint surfaces between the first or second
thermoelectric conversion element 2a, 2b and the first or second electrode 3a, 3b
have an exposed edge. This increases the joint strength between the thermoelectric
conversion elements and the electrodes, keeps down a decrease in joint strength due
to aging, and prevents production of cracks at the joint surfaces.
[0028] The second covering layer 5 does not necessarily need to cover the first and second
thermoelectric conversion elements 2a, 2b completely but may cover them partly, because
also in that case, the second covering layer can produce a temperature difference
between the first electrodes 3a and the second electrodes 3b, keep the temperature
difference constant, and increase the strength of the thermoelectric conversion module
1. Like the first covering layer 4, the second covering layer 5 may contain a material
functioning as a thermally-conducive material, although it is required that the second
covering layer 5 be lower in thermal conductivity than the first covering layer 4.
Although in the described example, the chief material for the first and second covering
layers 4, 5 is a resin, it may be a ceramic or the like. Also in that case, it is
required that the material covering the second electrodes 3b be lower in thermal conductivity
than the material covering the first electrodes 3a.
[0029] As shown in FIGS. 1 and 3, the support substrate 6 is joined to the second electrodes
3b to support the second electrodes 3b. The support substrate 6 is made of an insulating
material. The support substrate 6 may be a common insulating substrate such as a glass
epoxy substrate.
(Method for fabricating a thermoelectric conversion module)
[0030] A method for fabricating a thermoelectric conversion module 1 according to this embodiment
is as follows: First thermoelectric conversion elements 2a, second thermoelectric
conversion elements 2b, first electrodes 3a, second electrodes 3b, connecting electrodes
3c and extraction electrodes 3d are prepared and arranged between two punches functioning
as conducting pressing members in a fabricating apparatus. Then, pressure is applied
by pressing the punches to the first thermoelectric conversion elements 2a, second
thermoelectric conversion elements 2b, first electrodes 3a, second electrodes 3b,
connecting electrodes 3c and extraction electrodes 3d arranged between them while
current is applied. As a result, the first electrodes 3a, the second electrodes 3b,
the connecting electrodes 3c and the extraction electrodes 3d are diffusion-bonded
(plasma-bonded) to the first and second thermoelectric conversion elements 2a, 2b,
so that the first and second thermoelectric conversion elements 2a, 2b are connected
in series, thus forming a series circuit including five series circuit elements 13.
The application of pressure and current is performed within a vacuum chamber or a
chamber with a nitrogen gas atmosphere or an inert gas atmosphere.
[0031] Next, the first and second thermoelectric conversion elements 2a, 2b with the first
electrodes 3a, second electrodes 3b, connecting electrodes 3c and extraction electrodes
3d joined are mounted on a support substrate 6. More specifically, they are mounted
with the second electrodes 3b bonded to a metal pattern formed on the support substrate
6 by a bonding material such as solder. The support substrate 6 thus supports the
first and second thermoelectric conversion elements 2a, 3b with the first electrodes
3a, second electrodes 3b, connecting electrodes 3c and extraction electrodes 3d joined.
[0032] Next, a second covering layer 5 is formed by common insert molding, and then a first
covering layer 4 is formed by insert molding, likewise. By this process, the thermoelectric
conversion module 1 is completed.
(Comparison between an example piece according to the embodiment and a comparative
example piece)
[0033] Next, referring to table 1 below, test performed on a series circuit element 13 for
forming a thermoelectric conversion module 1 according to the above embodiment (hereinafter
referred to as "example piece") and a series circuit element prepared as a comparative
example (hereinafter referred to as "comparative example piece") having a structure
different from the series circuit element 13, and the result of the test will be described.
The comparative example piece differs from the example piece in that in place of the
first and second thermoelectric conversion elements 2a, 2a of stepped outer shape,
thermoelectric conversion elements of cylindrical shape are used. In the performance
comparison test, the example piece and the comparison example piece were heated to
80°C with a hand hot press, and resistance, voltage and electricity were measured
using a digital ohm meter. The example piece and the comparative example piece were
heated from the second electrode 3b side (which means the second cylindrical portion
12 side in the example piece).
[Table 1]
[0034]
Table 1: Performance comparison between example piece and comparative example piece
| |
Resistance (mΩ) |
Voltage (mV) |
Electricity (µW) |
| Example piece |
19 |
7.5 |
740 |
| Comparative example piece |
12 |
4.5 |
420 |
[0035] As shown in table 1, the example piece was higher in resistance, voltage and electricity
than the comparative example. From the performance evaluation based on the differences
in resistance, voltage and electricity, it was found that the example piece showed
an approximately 43% improvement in electricity generation performance as compared
with the comparative example piece. This is because in the example piece, heat is
applied to the side nearer to the second cylindrical portions smaller in volume, conducted
to the first cylindrical portions greater in volume and dissipated, so that an increase
in temperature of the first and second thermoelectric conversion elements 2a, 2b is
suppressed. The electricity generation temperature of the thermoelectric conversion
elements can be thus optimized by controlling conduction of heat from the heating
source only by means of the difference in volume between the first and second cylindrical
portions 11 and 12 of each thermoelectric conversion element, without changing the
material composition of each thermoelectric conversion element. Optimizing the electricity
generation temperature of the thermoelectric conversion elements improves the electricity
generation efficiency of the thermoelectric conversion elements, and thus, of the
thermoelectric conversion module 1.
[0036] As described above, in the present embodiment, the thermoelectric conversion elements
constituting the thermoelectric conversion module 1 each have a first cylindrical
portion (first structural portion) 11 and a second cylindrical portion (second structural
portion) 12 different in volume. The thermoelectric conversion elements having such
structure can be arranged with the second cylindrical portions 12 greater in volume
located nearer to the heating-source side, or high-temperature side (or in other words,
exposed to high temperature) and the first cylindrical portions 11 smaller in volume
located nearer to the low-temperature side (namely, away from the heating-source side,
or high-temperature side). This provides a possibility for controlling the conduction
of heat in the thermoelectric conversion elements to optimize the electricity generation
temperature of the thermoelectric conversion elements. In other words, in the thermoelectric
conversion module 1 and the thermoelectric conversion elements according to the present
embodiment, it is possible to optimize the electricity generation temperature of the
thermoelectric elements by a simple means, namely only adjusting their shape, without
changing their material composition, and thus, without entailing a significant increase
in cost. The present embodiment can thus provide a thermoelectric conversion module
1 which can maintain high electricity generation performance even when applied to
a relatively high-temperature heating source, and thermoelectric conversion elements
which do not exhibit a decrease in electricity generation performance even in a relatively
high-temperature environment.
(Variants of the thermoelectric conversion element)
[0037] In the described embodiment, the thermoelectric conversion element consists of a
first cylindrical portion 11 and a second cylindrical portion 12 different in volume.
The thermoelectric conversion element is however not limited to this structure, although
it is required that thermoelectric conversion element consist of a portion smaller
in volume located nearer to the high-temperature side when the thermoelectric conversion
module 1 is applied to a heating source and a portion greater in volume located nearer
to the low-temperature side thereof. For example, each thermoelectric conversion element
may have a cavity, as shown in FIGS. 6 and 7. FIGS. 6 and 7 schematically show variants
of the thermoelectric conversion element.
[0038] More specifically, the thermoelectric conversion element 31 (made of a p-type or
n-type semiconductor material) shown in FIG. 6 has a cylindrical outer shape. The
thermoelectric conversion element 31 can be considered to consist of an upper-side
first structural portion 31a and a lower-side second structural portion 31b, where
the first structural portion 31a and the second structural portion 31b are identical
in outer measurement and outer shape but only the second structural portion 31b has
a cylindrical cavity 32. Because of the cavity 32, the first structural portion 31a
is greater in volume than the second structural portion 31b although the first structural
portion 31a and the second structural portion 31b are identical in outer measurement
and outer shape.
[0039] The thermoelectric conversion element 41 (made of a p-type or n-type semiconductor
material) shown in FIG. 7 has a cylindrical outer shape and a cavity 42 of truncated
cone shape. Also the thermoelectric conversion element 41 can be considered to consist
of an upper-side first structural portion 41a greater in volume and a lower-side second
structural portion 41b smaller in volume.
[0040] The thermoelectric conversion elements 31, 41 shown in FIGS. 6, 7 can be arranged
with the second structural portion 31b, 41b smaller in volume located nearer to the
heating-source side, or high-temperature side and the first structural portion 31a,
41a greater in volume located nearer to the low-temperature side. This provides a
possibility for controlling the conduction of heat in the thermoelectric conversion
elements to optimize the electricity generation temperature of the thermoelectric
conversion elements.
[0041] The thermoelectric conversion element is not limited to a cylindrical outer shape
but may be, for example a quadrangular prism. Also in this case, it is required to
provide a difference in volume between a first structural portion and a second structural
portion of the thermoelectric conversion element by at least forming a cavity in the
second structural portion located nearer to the high-temperature side. The thermoelectric
conversion element may have an outer shape of a truncated cone or truncated pyramid,
thereby providing a difference in outer measurement, and thus, in volume between a
first structural portion and a second structural portion. Also in this case, the thermoelectric
conversion element may have an appropriate cavity.
Explanation of Reference Signs
[0042]
- 1
- Thermoelectric conversion module
- 2a
- First thermoelectric conversion element
- 2b
- Second thermoelectric conversion element
- 3a
- First electrode
- 3b
- Second electrode
- 3c
- Connecting electrode
- 3d
- Extraction electrode
- 4
- First covering layer
- 5
- Second covering layer
- 6
- Support substrate
- 11
- First cylindrical portion (first structural portion)
- 12
- Second cylindrical portion (second structural portion)
- 13
- Series circuit element