This application is based upon and claims the benefit of priority from Japanese Patent Application No. 2004-252838 filed on Aug. 31, 2004; the entire contents of which are incorporated herein by reference.
1. Field of the Invention
The present invention relates to a thermoelectric device capable of performing conversion between heat and electricity.
2. Description of the Related Art
Thermoelectric devices are devices utilizing thermoelectric effects, such as the Thomson effect, the Peltier effect, and the Seebeck effect. As temperature regulation units which convert electricity into heat, thermoelectric devices have been already put into mass production. Further, also as electric power generation units which convert heat into electricity, thermoelectric devices are being researched and developed. In a thermoelectric device, a plurality of thermoelectric elements are arranged between two insulating substrates having electrodes so as to be connected in series electrically and in parallel thermally.
In order to bring the electric power generation efficiency of the thermoelectric device closer to those of the thermoelectric elements themselves, it is necessary that heat be supplied to one end of the thermoelectric elements and radiated from the other end thereof in an efficient manner. Accordingly, for each of the insulating substrates, a ceramic substrate which is excellent in heat conduction is used. Moreover, the electrodes placed at ends of the thermoelectric elements are made of a material having low electric resistance. The electrodes and the thermoelectric elements are bonded to each other by use of solder.
However, since the melting point of solder is approximately 150 to 300° C., the heat resistance of the thermoelectric device has to be approximately 150 to 300° C. The temperature range in which the device can be used is thus limited, and there has been a problem that the device cannot be used in a high temperature environment of 300° C. or more.
An object of the present invention is to provide a thermoelectric device usable even in a high temperature environment of 300° C. or more and to provide a method of manufacturing the same.
A thermoelectric device according to a first aspect of the present invention includes: a first substrate and a second substrate each including a plurality of electrodes; and a plurality of thermoelectric elements placed between the first and second substrates, in a manner that one end and the other end of each of the thermoelectric elements correspond respectively to one of the electrodes of the first substrate and to one of the electrodes of the second substrate. Each of the electrodes of any one of the first and second substrates is bonded to one end of one of the thermoelectric elements corresponding to the electrode by use of gold.
In the present invention, the electrodes of any one of the first and second substrates and ends of the thermoelectric elements are bonded to each other by use of gold, the ends corresponding to the respective electrodes. This eliminates the necessity for solder and makes it possible to use the thermoelectric device until the melting point of gold is reached. Accordingly, the thermoelectric device can be used even in a high temperature environment of 300° C. or more, and the operating temperature range can be widened.
The thermoelectric device further includes a conductive member capable of accommodating expansion and contraction of the thermoelectric elements, and placed between each of the electrodes of one substrate different from the one that is bonded by the gold and one end of each of the thermoelectric elements corresponding to the electrode. The thermoelectric device further includes a lid placed outside to the second substrate and coupled to the first substrate so that pressure can be applied between the first and second substrates.
In the present invention, the conductive member capable of accommodating the expansion and contraction of the thermoelectric elements is provided between each of the electrodes of the substrate on which bonding using gold is not performed, and one end of one of the thermoelectric elements. Further, the lid is coupled to the first substrate so that pressure can be applied between the second and the first substrate, whereby the conductive member is held. Thus, the deformation and movement of the thermoelectric elements in a high-temperature state are accommodated by the conductive members. Accordingly, the thermoelectric elements and the like can be prevented from being damaged as compared with the case where the electrodes and ends of the thermoelectric elements are bonded to each other by use of solder.
In the thermoelectric device, the conductive member is placed between each of the electrodes of the first substrate and one end of each of the thermoelectric elements corresponding to the electrode.
In the present invention, by placing the conductive member between each of the electrodes of the first substrate and one end of one of the thermoelectric elements, in the case where heat is supplied to the second substrate through the lid, the elasticity of the conductive member can be successfully prevented from being deteriorated as compared with the case where the conductive member is placed between each electrodes of the second substrate and one of the thermoelectric elements. This is because the first substrate acts as a radiator plate and is at a lower temperature than the second substrate.
In the thermoelectric device, a portion formed by extending an edge of the lid is coupled to the first substrate.
In the present invention, coupling the portion formed by extending the edge of the lid to the first substrate eliminates the necessity of additionally providing a coupling member for coupling the lid and the first substrate. Thus, the manufacturing process can be simplified, and the manufacturing cost can be reduced.
In the thermoelectric device, the conductive member is welded to each of the electrodes at two or more positions per electrode.
In the present invention, by welding the conductive member at two or more positions per electrode, the movement of the conductive member is reduced as compared with the case where the conductive member is merely brought into contact with the electrode. Thus, stability of the device is improved, and variations in performance among the devices can be prevented.
In the thermoelectric device, the positions at which the conductive member is welded are positions on the electrodes, the positions different from portions in which the thermoelectric elements are placed.
In the present invention, the conductive member is welded at positions on each of the electrodes, the positions corresponding to portions in which the thermoelectric elements are not placed. This prevents thermal efficiency from being decreased by a reduction of the contact areas between the thermoelectric elements and the conductive member, the reduction otherwise resulting from the deformation of the shapes of the welded portions.
A thermoelectric device manufacturing method according to a second aspect of the present invention includes the steps of: placing gold on one end of each of a plurality of thermoelectric elements; placing gold on a plurality of electrodes of any one of a first substrate and a second substrate; bonding the gold on the thermoelectric elements and the gold on the electrodes of the foregoing substrate; and placing the substrate having the thermoelectric elements bonded thereto and other substrate so that the substrates may face each other with the thermoelectric elements interposed therebetween.
In the present invention, since gold is placed on one end of each of the plurality of thermoelectric elements and gold is also placed on the plurality of electrodes, solid state diffusion bonding of gold to gold can be performed.
It is desirable that the thermoelectric device manufacturing method further include the steps of: placing a conductive member capable of accommodating expansion and contraction of the thermoelectric elements between each electrode of one substrate different from the one that is bonded by the gold and one end of one of the thermoelectric elements corresponding to the electrode; and placing a lid outside to the second substrate, and coupling the lid to the first substrate so that pressure is applied between the first and second substrates.
In the step of coupling the lid to the first substrate, it is desirable that a coupling portion of the lid is welded to a welding metal pattern placed to surround all of the electrodes on the first substrate with a metal foil.
In the step of placing the conductive member, it is desirable that the conductive member be welded to each of the electrode at two or more positions per electrode. It is desirable that the positions at which the conductive member be welded are positions on the electrodes, the positions different from portions in which the thermoelectric elements are placed.
As shown in the cross-sectional view of
A surface of each electrode of the first substrates 14 or second substrates 4, one end of each thermoelectric element 10, and one end of each thermoelectric element 11 are plated with gold. In this embodiments, as one example, gold 7 is placed on the surface of each electrode 5 of the second substrate 4, and gold 12 is placed on the one end of each thermoelectric element 10, and the one end of each thermoelectric element 11. Further, the gold 7 on the electrodes 5 and the gold 12 on the thermoelectric elements 10 and 11 are bonded to each other by solid state diffusion.
Thus, in the thermoelectric device 1, the necessity for solder is eliminated by bonding the electrodes and the thermoelectric elements to each other by use of gold. Incidentally, as the gold used here, other than pure gold, gold having impurities mixed therein or gold alloy may be used.
Conductive members 6 capable of accommodating expansion and contraction of the thermoelectric elements 10 and 11 are placed between the electrodes 13 on the first substrate 14, on which bonding using gold is not performed, and ends of the thermoelectric elements 10 and 11, the ends being at positions corresponding to the electrodes 13. As these conductive members 6, for example, used are metal pieces obtained by knitting metal fibers into meshes so that deformation in the thickness direction is allowed. Note that this deformation may be any of elastic deformation and plastic deformation.
Moreover, a lid 2 placed outside to the second substrate 4 so as to cover the second substrate 4 is coupled to the first substrate 14 by a coupling member 9 so that pressure can be applied between the second substrate 4 and the first substrate 14. Thus, the lid 2 and the first substrate 14 are placed to face each other with the thermoelectric elements 10 and 11 interposed therebetween. Further, the second substrate 4, the electrodes 5 on the second substrate 4, and the conductive members 6 are held in the state where pressure is applied by the lid 2 and the first substrate 14 in a longitudinal direction of the thermoelectric elements 10 and 11, i.e., in a direction in which a current flows with the generation of an electromotive force.
In this thermoelectric device 1, the conductive members 6 are not fixed to the thermoelectric elements 10 and 11 but merely brought into contact therewith. Thereby, the movement and deformation of the thermoelectric elements 10 and 11 are accommodated by the conductive members 6 even in a case where, when the device is operated in a high temperature environment, the amount of deformation of each component differs from each other because of differences in linear expansion coefficients among the components or because of a difference in temperature between a heat absorption side and a heat radiation side. Thus, the bonding portions of the thermoelectric elements 10 and 11 and the thermoelectric elements themselves are prevented from being damaged. Further, since variations in height among the thermoelectric elements 10 and 11 are also accommodated by the conductive members 6, a step for selection, inspection, or the like according to height can be eliminated.
The thermoelectric device 1 can convert heat supplied to the lid 2 into electricity by use of the thermoelectric elements 10 and 11. By forming a metal film 40 between the lid 2 and the second substrate 4, heat absorption efficiency of the device is increased.
Further, the conductive members 6 are placed, not between the electrodes 5 of the second substrate 4 of a high temperature side to which heat is supplied and the thermoelectric elements 10 and 11, but between the electrodes 13 of the first substrate 14 of a heat-radiating low temperature side and the thermoelectric elements 10 and 11, whereby the deterioration of the elasticity of the conductive members 6 in a high temperature environment is reduced.
The lid 2 and the first substrate 14 are coupled to each other by use of a coupling member 9. The coupling member 9 is welded to a welding metal pattern 31 on the first substrate 14 with metal foil 30 interposed therebetween. This eliminates the necessity of brazing to the first substrate 14 a portion of the lid 2 which is to be coupled to the first substrate 14, and prevents the brazed portion from being damaged at the time of cooling after brazing at 900° C. in the manufacturing process.
The thermoelectric device 1 is a box structure sealed with the lid 2, the first substrate 14, and the coupling member 9. The inside of the box structure is set to be a reduced-pressure atmosphere so that the deformation or destruction of the structure does not easily occur even if the structure suffers a large temperature change. In order to maintain this atmosphere, the box structure is hermetically sealed.
As shown in the plan view of
As shown in the plan view of
Further, the positions at which each conductive member 6 is fixed by resistance welding are set to be positions different from the portions on one electrode 13 in which the thermoelectric elements 10 and 11 are placed. It is particularly desirable that, as shown in
An electromotive force generated in the thermoelectric elements 10 and 11 is extracted to the outside by way of a through hole 16 formed in the first substrate 14. As shown in
In the thermoelectric device 1, the voltage of an electromotive force is increased by electrically connecting the p-type thermoelectric elements 10 and the n-type thermoelectric elements 11 in series by use of the electrodes 13 of the first substrate 14 and the electrodes 5 of the second substrate 4. That is, a current flowing through the thermoelectric elements is extracted from the metal interconnection 18 after alternately passing through the p-type thermoelectric elements 10 and the n-type thermoelectric elements 11.
Incidentally, in this embodiment, the p type and the n type of the thermoelectric elements mean thermoelectric elements which are configured so that the respective directions of the current flows therein when heat is applied to ends of the thermoelectric elements may become opposite.
Next, one example of a process of manufacturing the thermoelectric device 1 will be described. First, as shown in the process drawing of
Subsequently, as shown in the process drawing of
Then, as shown in the process drawing of
Next, as shown in
Subsequently, as shown in
Then, as shown in
Next, as shown in
Finally, the thermoelectric device is left in a reduced-pressure atmosphere, and the sealing hole 3 is melted by a laser to be closed, whereby the thermoelectric device 1 having a hermetically sealed structure is obtained.
Thus, according to this embodiment, the electrodes 5 of the second substrate 4 and corresponding ends of the thermoelectric elements 10 and 11 are bonded to each other by use of gold. This eliminates the necessity for solder and makes it possible to use the thermoelectric device until the melting point of gold is reached. Accordingly, the operating temperature range can be widened.
According to this embodiment, the deformation and movement of the thermoelectric elements 10 and 11 are accommodated by the conductive members 6 by: providing the conductive members 6 capable of accommodating the expansion and contraction of the thermoelectric elements 10 and 11 between the electrodes 13 of the first substrate 14, on which bonding using gold is not performed, and the thermoelectric elements 10 and 11; and having the conductive members 6 being held by coupling the lid 2 to the first substrate 14 so that pressure can be applied between the lid 2 and the first substrate 14. Accordingly, the thermoelectric elements and the like can be successfully prevented from being damaged as compared with the case where the electrodes 13 and ends of the thermoelectric elements 10 and 11 are bonded to each other by use of solder.
According to this embodiment, the conductive members 6 are placed between the electrodes 13 of the first substrate 14 and ends of the thermoelectric elements 10 and 11. Accordingly, when heat is supplied to the second substrate 4 through the lid 2, the elasticity of the conductive members 6 can be successfully prevented from being deteriorated as compared with the case where the conductive members 6 are placed between the second substrate 4, which is the high temperature side, and the thermoelectric elements. This is because the first substrate 14 acts as a radiator plate and is at a lower temperature than the second substrate 4.
According to this embodiment, a coupling portion of the lid 2 which is to be coupled to the first substrate 14 is welded, with the metal foil 30 interposed therebetween, to the welding metal pattern 31 which is placed so as to surround all of the electrodes 13 on the first substrate 14. By doing so, the necessity of brazing this coupling portion to the first substrate 14 is eliminated, and the brazed portion can be prevented from being damaged at the time of cooling after brazing at 900° C. in the manufacturing process. This improves the reliability of the first substrate 14. Consequently, the reliability of the completed thermoelectric device can be improved.
According to this embodiment, the conductive members 6 are welded to the electrodes 13 at two or more positions for each electrode 13. By doing so, the movement of the conductive members 6 is reduced as compared with the case where the conductive members 6 are merely brought into contact with the electrodes 13. Accordingly, stability of the device is improved, and variations in performance among the devices can be prevented.
According to this embodiment, the conductive members 6 are welded at positions different from to the portions on the electrodes 13 in which the thermoelectric elements 10 and 11 are placed. This prevents thermal efficiency from being decreased by a reduction of the contact areas between the thermoelectric elements 10 and 11 and the conductive members 6, the reduction otherwise resulting from the deformation of the shape of the welded portions.
Incidentally, in this embodiment, SUS304 is used as the material of the lid 2, nickel is used for the metal foil 30, and copper is used for the electrodes 13 of the first substrate 14. However, these materials are not particularly limited as long as the effects of this thermoelectric device, such as the airtightness of the welded portion and the processability of the lid 2, can be obtained. Further, the metal foil 30 may be omitted as long as the airtightness of the welded portion can be obtained. Moreover, each welding method is not particularly limited to laser welding or resistance welding as long as the effects of the present invention can be obtained.
Further, in this embodiment, the electrodes 5 on the second substrate 4 and the thermoelectric elements 10 and 11 are bonded to each other by use of gold, and then the conductive members 6 are placed between the electrodes 13 on the first substrate 14 and the thermoelectric elements 10 and 11. However, in contrast to this, it is acceptable to bond the electrodes 13 on the first substrate 14 and the thermoelectric elements 10 and 11 by use of gold and then to place the conductive members 6 between the electrodes 5 on the second substrate 4 and the thermoelectric elements 10 and 11.
Furthermore, in this embodiment, the portion with which the lid 2 is to coupled to the first substrate 14 is welded to the welding metal pattern 31 with the metal foil 30 interposed therebetween. However, this is not limited to the metal foil 30. For example, the top of the metal pattern 31 may be plated with a brazing material instead of the metal foil 30.
Next, a thermoelectric device in another embodiment will be described. As shown in the cross-sectional view of
According to this embodiment, coupling the portion formed by extending the edge of the lid 2 to the first substrate 14 eliminates the necessity of additionally providing a coupling member for coupling the lid 2 and the first substrate 14. Thus, the manufacturing process can be simplified, and the manufacturing cost can be reduced.
Incidentally, in each of the above-described embodiments, a description has been given by taking as an example a thermoelectric device which converts heat supplied to the lid 2 into electricity. However, the present invention can also be applied to a thermoelectric device which converts electricity into heat.
Number | Date | Country | Kind |
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2004-252838 | Aug 2004 | JP | national |