THERMOELECTRIC CONVERSION MATERIAL AND METHOD OF PRODUCTION THEREOF
20170263839 · 2017-09-14
Inventors
- KEN KUROSAKI (Osaka, JP)
- SHINSUKE YAMANAKA (Hyogo, JP)
- YUSUFU AIKEBAIER (Fukui, JP)
- SEONGHO CHOI (Osaka, JP)
- JUNYA TANAKA (Osaka, JP)
- Satoshi Maeshima (Kyoto, JP)
Cpc classification
International classification
Abstract
Provided herein is a skutterudite-type material having high thermoelectric conversion characteristics in a high temperature region. A thermoelectric conversion material is provided that contains a skutterudite-type material represented by the following composition formula (I)
I.sub.xGa.sub.yM.sub.4Pn.sub.12 (I),
wherein x and y satisfy 0.04≦x≦0.11, 0.11≦y≦0.34, and x<y, I represents one or more elements selected from the group consisting of In, Yb, Eu, Ce, La, Nd, Ba, and Sr, M represents one or more elements selected from the group consisting of Co, Rh, Ir, Fe, Ni, Pt, Pd, Ru, and Os, and Pn. represents one or more elements selected from the group consisting of Sb, As, P, Te, Sn, Bi, Ge, Se, and Si.
Claims
1. A thermoelectric conversion material comprising a skutterudite-type material represented by the following composition formula (I)
I.sub.zGa.sub.yM.sub.4Pn.sub.12 (I) wherein: x and y satisfy
0.04≦x≦0.11,
0.11≦y≦0.34, and
x<y I represents one or more elements selected from a group of elements including: In, Yb, Eu, Ce, La, Nd, Ba, and Sr, M represents one or more elements selected, from a group of elements including; Co, Rh, Ir, Fe, Ni, Pt, Pd, Ru, and Os, and Pn represents one or more elements selected from a group of elements including: Sb, As, P, Te, Sn, Bi, Ge, Se, and Si.
2. The thermoelectric conversion material according to claim 1, wherein I is In, M is Co, and Pn is Sb in the composition formula (I).
3. The thermoelectric conversion material, according to claim 2, which further comprises particles containing at least Ga, and having an average particle size of not more than 1 μm and not less than 1 nm.
4. A method for producing a thermoelectric conversion material containing a skutterudite-type material represented by the following composition formula (I)
I.sub.xGa.sub.yM.sub.4Pn.sub.12 (I), wherein: x and y satisfy
0.04≦x≦0.11,
0.11≦y≦0.34, and
x<y, I represents one ox more elements selected from a group of elements including: In, Yb, Eu, Ce, La, Nd, Ba, and Sr, M represents one or more elements selected from a group of elements including: Co, Rh, Ir, Fe, Ni, Pt, Pd, Ru, and Os, and Pn represents one of more elements selected from a group of elements including: Sb, As, P, Te, Sn, Bi, Ge, Se, and Si, the method comprising: charging a mixture of the elements represented by I, M, and Pn, and Ga of the composition formula (I) into a container; heating the container, and melting the mixture at a first temperature to obtain a molten mixture; quenching the molten mixture to form a solid; and heating the solid in a heat treatment at a second temperature lower than the first temperature to obtain the skutterudite-type material represented by the composition formula (I).
5. The method according to claim 4, wherein I is In, M is Co, and Pn is Sb in the composition formula (I).
6. The method according to claim 5, which further comprises particles containing at least Ga, and having an average particle size of not more than 1 μm and not less than 1 nm.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0018]
[0019]
[0020]
[0021]
[0022]
[0023]
[0024]
[0025]
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0026] An illustrative embodiment of the present disclosure is described below with reference to the accompanying drawings.
Thermoelectric Conversion Material
[0027] An embodiment of the present disclosure relates to a thermoelectric conversion material containing a skutterudite-type material. The skutterudite-type material is a cubical crystal solid solution of a composition represented by M.sub.4Pn.sub.12, where M is an element in Group VIII of the periodic table, and Pn is an element in group IVB, VB, or VIB of the periodic table. Examples of the elements represented by M include Co, Rh, Ir, Fe, Ni, Pt, Pd, Ru, and Os. Examples of the elements represented by Pn include Sb, As, P, Te, Sn, Bi, Ge, Se, and Si.
[0028] The crystal lattice of the skutterudite-type material has one empty lattice per M.sub.4Pn.sub.12. All of or some of the empty lattices may be filled with rare earth elements such as La, Ce, and Yb, alkali earth elements such as Ba, and Ca, or earth, metal elements such as Tl, In, and Sn. A material filled with these elements has a composition represented by L.sub.xM.sub.4Pn.sub.12 (where L.sub.x is the element introduced to the empty lattice, and 0<x≦1), and is called a filled skutterudite-type material.
[0029] The material contained in the thermoelectric conversion material of the embodiment of the present disclosure is of a filled skutterudite type, and has a structure in which two elements are added in combination. Specifically, the material is a double filled skutterudite-type material. As used, herein, “skutterudite-type material” encompasses a filled skutterudite-type material (including a double filled skutterudite-type material).
[0030] Specifically, the thermoelectric conversion material of the embodiment of the present disclosure contains a double filled skutterudite-type material represented by the following composition formula (I).
I.sub.xGa.sub.yM.sub.4Pn.sub.12 (I)
[0031] In the composition formula (I), x satisfies 0.04≦x≦0.11, preferably 0.09≦x≦0.11. The subscript y satisfies 0.11≦y≦0.34, preferably 0.26≦y≦0.34. Here, x<y. By satisfying these ranges, it is possible to achieve desirable performance as expected from, the power factor (PF) indicative of thermoelectric conversion performance, as will be described later in Examples 1 to 4. A more desirable thermoelectric conversion material can be obtained when x and y in the composition formula (I) satisfy the ranges of Examples 3 and 4 of higher PF values.
[0032] In the composition formula (I), I represents one or more elements selected from the group consisting of In, Yb, Eu, Ce, La, Nd, Ba, and Sr. M represents one or more elements selected from the group consisting of Co, Rh, Ir, Fe, Ni, Pt, Pd, Ru, and Os. Pn. represents one or more elements selected from the group consisting of Sb, As, P, Te, Sn, Si, Ge, Se, and Si.
[0033] Note, however, that M is preferably Co, and Pn is preferably Sb from the standpoint of, for example, thermoelectric conversion performance. It is particularly preferable from the standpoint of stable material quality that the skutterudite-type material is double filled with In and Ga. Specifically, it is particularly preferable that the skutterudite-type material is Co.sub.4Sb.sub.12 with the added elements Ga and In, specifically In.sub.zGa.sub.yCo.sub.4Sb.sub.12. Typically, the skutterudite-type material is filled with rare earth elements (such as Yb, Ce, and La). However, these are difficult to handle as they undergo rapid oxidation even at ordinary temperature, and require storage in oil. It is therefore preferable for stable material quality that the skutterudite-type material be double filled with In.
[0034] The following describes a skutterudite-type material containing a thermoelectric conversion material according to the embodiment of the present disclosure in which the elements represented by I, M, and Pn are In, Co, and Sb, respectively, in the composition formula (I). However, the skutterudite-type material of the present disclosure is not limited to the material containing these elements.
[0035] The skutterudite-type material according to the embodiment of the present disclosure is one obtained by adding a combination of In and Ga to the common skutterudite-type material Co.sub.4Sb.sub.12. The material of the embodiment is represented by the composition formula In.sub.xGa.sub.yCo.sub.4Sb.sub.12 (II), where x is a variable between 0.4 and 0.11, and y is a variable between 0.11 and 0.34. Here, x and y are adjusted to satisfy x<y.
[0036] The skutterudite-type material of the embodiment of the present disclosure is described below using the materials (Examples 1 to 4) represented by the following composition formula.
[0037] Example 1: In .sub.0.04Ga.sub.0.11Co.sub.4Sb.sub.12
[0038] Example 2: In .sub.0.06Ga.sub.0.10Co.sub.4Sb.sub.12
[0039] Example 3: In .sub.0.09Ga.sub.0.20Co.sub.4Sb.sub.12
[0040] Example 4: In .sub.0.11Ga.sub.0.34Co.sub.4Sb.sub.12
[0041] These materials were compared to a material (Comparative Example 1) that does not contain In or Ga, a material (Comparative Example 2) of the composition Co.sub.4Sb.sub.12 with only one additional element Ga, and a material (Comparative Example 3) of the composition Co.sub.4Sb.sub.12 with additional elements In and Ga and in which x and y in the composition formula do not satisfy the foregoing ranges.
[0042] Comparative Example 1: Co.sub.4Sb.sub.12
[0043] Comparative Example 2: Ga.sub.0.2Co.sub.3Sb.sub.12
[0044] Comparative Example 3: In.sub.0.01Ga.sub.0.04Co.sub.4Sb.sub.12
[0045] The materials of the foregoing composition formulae of Examples 1 to 4 and Comparative Examples 1 to 3 were measured for Seebeck function 5 electrical resistivity ρ, and thermal conductivity κ in a temperature range of from room temperature to 500° C. The Seebeck coefficient S and the electrical resistivity ρ were measured with the ULVAC product ZEM3 . The thermal conductivity κ was measured according to a laser flash method using the ULVAC product TC-700.
[0046] The electrical resistivity is described first, with reference to
[0047] By focusing on the relation between temperature and electrical resistivity shown in
[0048] The Seebeck coefficient S is described below with reference to
[0049] The power factor is described below with reference to
[0050] As shown, in
[0051] Ga has smaller effects on electrical resistivity and Seebeck coefficient, than In, as described above. The following describes the effect of Ga on thermal conductivity as a characteristic feature of the embodiment of the present disclosure.
[0052]
[0053] Here, the lattice constant is different for crystals containing Co.sub.4Sb.sub.12, and crystals of particles containing Ga which precipitates on the surface (Ga crystals, or crystals of an alloy of Ga with In or Sb). This creates strain at the crystal interface. The strain effectively scatters phonons that cause heat conduction, and makes the thermal conductivity smaller. Referring to
[0054]
[0055]
[0056] In the embodiment of the present disclosure, a thermoelectric conversion material of the same characteristics obtained in Example 4 can be obtained when the material satisfies the composition formula (II).
[0057] The thermoelectric conversion material of the present disclosure may additionally contain other materials, as required, as long as the skutterudite-type material is contained as a main material. As used herein, “skutterudite-type material contained as a main material” means that the skutterudite-type material is more than 50 mass % of the total mass of the thermoelectric conversion material.
Thermoelectric Conversion Material Producing Method
[0058] A method for producing the thermoelectric conversion material of the embodiment of the present disclosure is described below. The thermoelectric conversion material of the embodiment of the present disclosure can be produced by charging a mixture of In, Ga, Co, and Sb into a container, heating the container and melting the mixture at a first temperature, quenching the molten, mixture to form a solid, and heating the solid in a heat treatment at a second temperature lower than the first temperature to obtain a skutterudite-type material of the desired composition formula. The following descriptions of the producing method are based on the material of Example 4 (In.sub.0.11Ga.sub.0.34Co.sub.4Sb.sub.12). However, the materials of Examples 1 to 3, and materials of the composition formula (I) containing different elements also may be produced in the same manner by adjusting the materials or the mixture ratio.
[0059] Simple substance metals In, Ga, Co, and Sb are used as starting materials. The pure metals In, Ga, Co, and Sb are charged into a quartz tube in a weight ratio In:Ga:Co:Sb of 0.401:1:17.75:40.08. Here, the calculation of the weight ratio of In, Ga, Co, and Sb is based on specific gravities 7.31, 5.9, 8.9, and 6.7, respectively. Preferably, the quartz tube is filled with an inert gas such as argon, or a vacuum is created inside the quarts tube to prevent oxidation of the materials. it is also preferable to keep the quartz tube highly airtight to prevent entry of oxygen into the quartz tube after charging the materials. The container used to contain the material mixture is not limited to the quartz tube, and any container may be used, as long as it can be kept airtight. For example, a metallic container may be used.
[0060] The quartz tube with the sealed mixture is heated with an electric furnace at a temperature (first temperature) between 1,050° C. and 1,300° C. In the embodiment of the present disclosure, the ratio of Co to Sb is 1:3 in terms of an atomic concentration, and the alloy has a melting point in the vicinity of about 1,000° C. Accordingly, the heating temperature (first temperature) is set at or above this melting point. Considering the heat resistance of the container, and the vaporization of metal, the heating temperature is set so that the maximum heating temperature does not become excessively high. The heating time is not particularly limited, as long as an alloy of Co and Sb can be formed.
[0061] The heated molten mixture is cooled into a solid. The method of cooling the mixture is not particularly limited. However, it is preferable to quench the mixture, for example, by dipping the mixture inside the quartz tube in water bath. Here, the starting simple substance metals have mixed and formed an alloy after being heated as above. It is known that the crystal grain size varies as the molten metal cooling rate increases, irrespective of the thermoelectric conversion material. The particle size of the solid can thus be reduced by quenching the mixture. By reducing the particle size of the solid, it becomes easier to obtain a thermoelectric conversion material having a skutterudite-type crystalline structure, as will be described later.
[0062] The solid is then subjected to a heat treatment at a temperature (second temperature) below the first temperature. Specifically, the solid is heated at a temperature (second temperature), between 500° C. and 800° C., using the same electric furnace used to melt the mixture. Here, the solid may be heated inside or outside of the quartz tube. When heating the solid outside of the quartz tube, the electric furnace is filled with an inert gas, or a vacuum atmosphere is created therein, to prevent the mixture from being oxidized.
[0063] The solid before the heat treatment at the second temperature is not in a state of skutterudite-type crystals, and In and Ga exist as a mixture with metals such as CoSb.sub.2 and Sb. In other words, the solid does not have the thermoelectric conversion material characteristics in this state. Heating at the second temperature reconstitutes the mixture into a crystal form, and creates the desired skutterudite structure. Preferably, the crystal grains of metals such as CoSb.sub.2 and Sb are finely dispersed before the heat treatment at the second temperature. Heating at the second temperature is performed in a solid state. It is accordingly difficult to form skutterudite-type crystals when Sb is segregated as large crystal grains, and reacts with, for example, CoSb.sub.2. Because the mixture does not melt at the second temperature, the atoms are not fluidic, and move inside the crystals by diffusion. A structural change to skutterudite-type crystals thus becomes more likely, and it takes place more uniformly when the solid before the heat treatment is a fine solid.
[0064] The heat treatment time at the second temperature may be, for example, 10 hours to 168 hours, though it depends on the state of crystal grain size. As a rule, a thermoelectric conversion material of stable characteristics can be obtained when the heat treatment is performed for a longer time period.
[0065] The thermoelectric conversion material having thermoelectric conversion characteristics of the embodiment of the present disclosure can be obtained after these steps.
[0066] The thermoelectric conversion material of the embodiment of the present disclosure may have a powder form, and may be subjected to sinter molding. The material may be remelted, molded into a specified shape by being drawn into a glass tube or the like, and mounted on a substrate after being separated into individual pieces. A practical thermoelectric conversion module can be obtained by molding the material into a desired shape in this fashion.
[0067] Although the present disclosure has been described with reference to the aforementioned embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments as well as alternative embodiments of the invention will become apparent, to persons skilled in the art. It is therefore contemplated that the appended claims will cover any such modifications or embodiments.
INDUSTRIAL APPLICABILITY
[0068] The thermoelectric conversion material according to the embodiment of the present disclosure has more desirable thermoelectric conversion characteristics than thermoelectric conversion materials of related art, and is applicable for recovery of high-temperature energy such as, for example, in automobiles, in recovery of exhaust heat in factories, . . . etc.