The present invention relates to a thin-film thermoelectric conversion element and a manufacturing method for that thin-film thermoelectric conversion element.
In recent years there has been increasing international concern over the issue of reducing carbon dioxide which is a substance causing the global warming phenomenon. Continuous progress is being made in technical innovations for shifting from resource energy that discharges large quantities of carbon dioxide, to reusable next generation energy such as natural energy and thermal energy. Next generation energy technology candidates includes technology utilizing natural energy such as solar power and wind power, and reusable technology for reutilizing the lost portion of primary energy such as heat and vibration emitted from using resource energy. Though conventional resource energy is a centralized energy mainly in the form of large-scale electrical generating facilities; next generation energy is featured by an uneven distribution of both natural energy and reusable energy. In current energy utilization, the energy that is waste-discharged without being used amounts to approximately 60% of primary energy and that amount is mainly in the form of waste heat. Therefore, what is needed besides increasing the proportion of next generation energy among primary energy is improved energy reutilization technology and in particular, better power conversion technology for waste heat energy. Waste heat is generated in all manner of situations so reutilizing waste heat energy requires an electrical generating system with a high degree of universality in all types of installation formats. Contriving such a generating system requires developing thermoelectric conversion materials possessing high electromotive force and in a space-saving format such as film.
This thermoelectric conversion material is an element utilized for thermoelectric cooling by using the Peltier effect and generating thermoelectric power by way of the Seebeck effect. These elements generally possess a structure where plural P-type thermoelectric material and plural N-type thermoelectric material that is alternately arrayed and coupled in series.
The currently used thermoelectric conversion material for actual applications is bismuth telluride (Bi2Te3). The conversion efficiency of bismuth telluride is high but both bismuth and telluride are expensive, and tellurium is toxic so bismuth telluride is not a suitable choice in terms of the goals of mass production, low-cost, and reducing the load on the environment. So a substitute high-efficiency thermoelectric conversion material is needed as a substitute for bismuth telluride (Bi2Te3). These circumstances have focused attention on Fe2VAl-based alloy as a potential thermoelectric conversion material that is both non-toxic and inexpensive.
Methods for producing these thermoelectric conversion materials involved fusing or sintering by heating the raw material, and mechanically processing (cutting out) the material into a block shape. The advantage provided by this method is that the crystalline structure and elemental composition of the crystal can be controlled. However, most thermoelectric conversion materials have low mechanical strength so that intricate and precise processing is difficult, and achieving a thin and compact material was impossible. Moreover another problem was that the processing to cut-out the block had a low product yield. These circumstances served to focus attention on methods for manufacturing thermoelectric conversion material into thin film. A thermoelectric conversion material formed into a thin film can be formed into a thin-film thermoelectric conversion material possessing a fine and intricate structure, and extremely tiny and thin thermoelectric conversion elements can be made. These tiny and thin thermoelectric conversion elements could be mounted even in narrow spaces impossible for block-shaped elements to fit. A high-efficiency, thin-film thermoelectric conversion element suitable for practical use is therefore needed.
Japanese Unexamined Patent Application Publication No. 2005-277343 discloses a thermoelectric conversion element utilizing an Fe2VAl-based thermoelectric material thin film deposited over a heated substrate. The disclosed element is a 5 μm thick N-type thermoelectric material sections and P-type thermoelectric material sections alternately arrayed in a zigzag pattern over a flat substrate. The thickness of the thermoelectric material thin film is preferably between 0.1 to 100 μm.
The performance index for thermoelectric conversion material is typically a dimensionless quantity called XT, and is given as follows.
Here, S denotes the Seebeck coefficient, κ is the thermal conductivity, ρ is the resistivity, and T equals the room temperature (300K). The larger the Seebeck coefficient, and the smaller the thermal conductivity and electrical resistivity, the larger the performance index becomes. The Seebeck coefficient and the electrical resistivity are physical quantities determined by the electron state of the material. According to Mott's formula, the Seebeck coefficient has a relation as shown next.
According to formula 2, the Seebeck coefficient is inversely proportional to the absolute value of the density of states in the Fermi level, and is proportional to that energy gradient. Therefore, a material with a small density of states (hereafter DOS) in the Fermi level and whose DOS rise fluctuates drastically signifies a material with a high Seebeck coefficient. Moreover in regards to electrical resistivity has the following relation.
Here. λF and νF denote the mean free path and velocity of electrons at the Fermi level. This relation is inversely proportional to DOS of formula 3 so the electrical resistivity is small when there is a Fermi level where DOS of the absolute value is at a large energy position.
The thermoelectric conversion material of Fe2VAl-based alloy possesses a pseudogap band structure. A pseudogap band structure is a matter or material system with an electronic state where the DOS in the vicinity of the Fermi level has drastically dropped. One feature of the Fe2VAl-based alloy band structure is said to be behavior as a rigid band model where only the Fermi level energy position changes and also that no significant fluctuations in the band structure occur when the composition ratio of the compound is changed. Therefore, by changing the composition ratio of the compound or changing the composition of the compound for hole doping or electron doping, the Fe2VAl-based alloy can control the Fermi level at the energy position to make steep changes in DOS and moreover attain an optimal absolute value for DOS for optimizing the relation between the Seebeck coefficient and resistivity. The above DOS changes and optimal values can be achieved in both a P-type and N-type matter system.
Under current circumstances however, the FeiVAl-based compound has large thermal conductivity near that of metal at room temperatures and higher and is still far away from attaining a practical performance index figure.
In view of the above problems and from results of extensive research, the present invention has the object of providing a thermoelectric conversion element as an element module with improved utility that possesses an enhanced performance index by utilizing the drop in thermal conductivity in Fe2VAl-besed alloy thin-film as an operating condition.
A representative example of the thermoelectric conversion element of the present invention is featured in including a buffer layer, a thermoelectric conversion material layer, and an electrode layer laminated over a substrate, and in which the thermoelectric conversion material layer is a thin film in a range from 1 nm to 200 nm in film thick comprised of Full-Heusler alloy or an alloy with elements replaced from Full-Heusler alloy.
Another feature of the present invention is a thermoelectric conversion element comprised of a plurality of layers of the above described thermoelectric conversion material layer and possessing a structure to obtain a total electromotive force that is the sum of the electromotive force in each layer. Specific features are the points that a plurality of single-unit structures comprised of laminated thermoelectric conversion material layer and a conductive buffer layer, are repeatedly deposited (formed); and that a lower electrode is coupled to the lowermost buffer layer for extracting the summed output of the electromotive force for each of the thermoelectric conversion material layers when a temperature gradient is applied in a direction perpendicular to the film plane, and that an upper electrode is deposited over the uppermost thermoelectric conversion material layer.
Another specific feature is the point that the invention is comprised of multilayer structure layer comprised of a plurality of N-type thermoelectric conversion material layers and insulator layers alternately and repetitively formed with an insulator layer interposed between them, over a buffer layer deposited over the substrate; and a lower electrode coupled to one end of an N-type thermoelectric conversion material layer within the single-unit structure of the lowermost section; a plurality of coupling electrodes are coupled successively and moreover at alternative positions at both ends of the thermoelectric conversion material layers laminated adjacent to the upper section, a coupling electrode for example couples the other end of the N-type thermoelectric conversion material layer to one end of the P-type thermoelectric conversion material layers; and a coupling electrode couples the other end of that P-type thermoelectric conversion material layer (however the end side where the above described lower electrode is coupled) to one end of the P-type thermoelectric conversion material layer above that coupled P-type thermoelectric conversion material layer; and an upper electrode is then coupled to the P-type thermoelectric conversion material layer within the single-unit structure of the uppermost section.
The material for the above described thermoelectric conversion material layer was Full-Heusler alloy or an alloy with elements replaced from Full-Heusler alloy, however the term Fe2VAl-based alloy may also be utilized. Besides Fe2VAl-based alloy other typical compounds for the material may include Fe2TiSn. Fe2TiSi, or Fe2NbAl; and more specifically an alloy whose composition is Fe2N1-xMxX1-xYx (however, N or M=V, Nb, Ti, Mo, W, Zr, and also X or Y═Al, Si, Sn, Ge).
The Seebeck coefficient and the electrical conductivity of the Fe2VAl-based alloy can be optimally controlled by replacing the elements to alter the electron state. However, at room temperatures, the Fe2VAl-based alloy has properties resembling those of metal so that the thermal conductivity becomes large. Attaining ZT=2 which is said to be the boundary for practical use requires lowering this thermal conductivity.
The thermal conductivity κ is expressed as follows.
Here, ζ or zeta is the density of the material, d is the sample film thickness, Cp is the sample specific heat at constant pressure, if is the time for the heat to propagate from the rear side of the thin film sample with a thickness d to the front side. As can be understood from formula 4 and formula 5, the thinner the sample film thickness, the smaller the thermal conductivity becomes. Heat is conveyed within a substance by way of electrons or lattice vibrations. Heat propagation by way of electrons is determined by the electron density within the substance. Heat propagation by way of lattice vibration is determined by the type of element and the crystalline structure. In other words, the change in thermal conductivity induced by controlling the thickness of the thin film is a property unique to the particular substance. The Physical Review B, 82, 075418, for example reported a change in thermal conductivity characteristics relative to the film thickness of copper (Cu). In this example, one can understand that at a film thickness of 100 nm or less, the thermal conductivity is proportional to the film thickness. However, as the film thickness approaches 200 nm, this proportional relation has already been lost and that thermal conductivity relative to increased film thickness is asymptotic to bulk thermal conductivity. In other words in copper (Cu) no clear effect in reducing thermal conductivity appears even if the film thickness was reduced at the vicinity of 200 nm.
Whereupon the present inventors, sought to ascertain the thermal conductivity characteristics of Fe2VAl-based alloy relative to changes in film thickness and verified the correct film thickness for obtaining a clear reduction in thermal conductivity.
If the film thickness range of the Fe2VAl-based alloy could be further narrowed to 100 nm or lower, then a thin film will possess a thermal conductivity less than one-fourth that of the bulk thermal conductivity, and the performance index as a thermoelectric conversion element can be increased to a higher level. Moreover, at a film thickness of 50 nm, the value for a performance index XT was confirmed as approximately 10 times that of bulk thermal conductivity.
The present invention therefore achieves a thermoelectric conversion element possessing a high performance index by utilizing material having a small environmental load and moreover by selecting film thickness conditions and contriving a suitable structure.
Each layer was deposited over the silicon substrate 100 utilizing the sputtering method along with argon (Ar) gas. The tantalum (Ta) was formed as a film in an amorphous state over the heat-oxidized silicon substrate at room temperature. After forming the laminated film, the laminated film was stripped away to directly above the buffer layer 101, then the thermoelectric conversion material layer 102 and the electrode layer 103 was cut out over the buffer layer by using electron beam (EB) lithography and ion beam etching. Silicon dioxide (SiO2) was formed as a film over the upper surface, a resist coating was applied, and electron beam (EB) lithography and ion beam etching were used in the forming process. Measuring the voltage across die electrodes showed that an electromotive force was generated when the substrate was in contact with a high-temperature section and generated a temperature gradient perpendicular to the element. Needless to say, wiring was formed in order to extract the respective voltages from the lower electrode and upper electrode.
The thermal conductivity for various Fe2Val thin-film thicknesses was found for the present embodiment. Those results are as shown in
In the example of the present embodiment, Fe2VAl was utilized as the thermoelectric conversion material, however other material may be utilized if a Full-Heusler alloy. Namely, besides Fe2VAl, other material may include Fe2TiSn, Fe2TiSi, or Fe2NbAl, etc., or an alloy whose composition is Fe2N1-xMxX1-xYx (however N or M=V, Nb, Ti, Mo, W, Zr, and also X or Y═Al, Si, Sn, Ge) will render the same effect.
Each layer was deposited over the silicon substrate 200 utilizing the sputtering method along with argon (Ar) gas. The tantalum (Ta) was formed as a film in an amorphous state over the heat-oxidized silicon substrate at room temperature. After forming the laminated film, the laminated film was stripped away to directly above the first buffer layer 201 in
The second embodiment provides an improved performance index by lowering the thermal conductivity in thermoelectric conversion material with a film thickness in a range from 1 nm to 200 nm the same as in the first embodiment. This effect is drastically evident at film thicknesses below 100 nra. Moreover in this embodiment, the number of laminations of thermoelectric conversion material thin film can be changed to match the required voltage.
The present embodiment utilized Fe2VAl as an example of the thermoelectric conversion material, however other material may be utilized if a Full-Heuslcr alloy. Namely, besides Fe2VAl, other material may include Fe2TiSn, Fe2TiSi, or Fe2NbAl, etc., or an alloy whose composition is Fe2N1-xMxX1-xYx (however N or M=V, Nb, Ti, Mo, W, Zr, and also X or Y═Al, Si, Sn, Ge) will render the same effect.
Besides silver (Ag), the material utilized in the second buffer layer may include: Cu, Au, Pt, Pd, Ru, Rh. Ta, W, V, Ti, and Mg.
In the structure of the above third embodiment and its variation, when the substrate 300 contacts a high temperature section, a temperature gradient is generated along the internal plane of each layer in the element causing an electromotive force to occur in each layer of the Fe2VAl. The voltages of the N-type Fe2VAl and P-type Fe2VAl attain opposite states. A voltage is obtained that is the sum of the electromotive forces of each Fe2VAl layer between the electrode 305 and electrode 307 sequentially coupled by the above described coupling electrodes. The third embodiment and variation of the third embodiment are in this way thermoelectric conversion elements that generate an electromotive force when a temperature gradient is applied along the internal plane in each layer and the utilization of the element differs from the second embodiment. The same points in the first embodiment and the second embodiment also apply to the film thickness of each thermoelectric conversion layers in the present embodiment. Namely, by controlling the film thickness to lower the thermal conductivity, a performance index ZT value is attained that is definitely improved compared to bulk material Fe2VAl which is exactly the same as previously described in the first embodiment and the second embodiment so that the practicality of the thermoelectric conversion element is improved.
The present embodiment need not utilize only Fe2VAl as the thermoelectric conversion material and other material may be utilized if a Full-Heusler alloy. Other possibilities include Fe2TiSn, Fe2TiSi, or Fe2NbAl, etc. Still other possibilities are alloys whose composition is Fe2N1-xMxX1-xYx (however, N or M=V, Nb, Ti, Mo, W, Zr, and also X or Y═Al, Si, Sn, Ge) will render the same effect.
Besides MgO, the insulator layer 303 may also utilize Al2O3, and SiO2, etc.
The present invention therefore provides a thermoelectric conversion element posing a low environmental load, ideal for mass production and moreover compact and with high performance and capable of practical use in many areas.
Number | Date | Country | Kind |
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2011-152460 | Jul 2011 | JP | national |
The present application claims priority from Japanese patent application JP 2011-152460 filed on Jul. 11, 2011, the content of which is hereby incorporated by reference into this application. This application is related to U.S. application Ser. No. 13/338,740 filed on Dec. 28, 2011, the disclosure of which is hereby incorporated by reference.