US20110036099A1 - Method for producing a thermoelectric intermetallic compound - Google Patents

Method for producing a thermoelectric intermetallic compound Download PDF

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US20110036099A1
US20110036099A1 US12/809,041 US80904108A US2011036099A1 US 20110036099 A1 US20110036099 A1 US 20110036099A1 US 80904108 A US80904108 A US 80904108A US 2011036099 A1 US2011036099 A1 US 2011036099A1
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intermetallic compound
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Mazhar Ali Bari
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BIOMETRIC TECHNOLOGY SOLUTIONS Ltd
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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C12/00—Alloys based on antimony or bismuth
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10N—ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10N10/00—Thermoelectric devices comprising a junction of dissimilar materials, i.e. devices exhibiting Seebeck or Peltier effects
    • H10N10/80—Constructional details
    • H10N10/85—Thermoelectric active materials
    • H10N10/851—Thermoelectric active materials comprising inorganic compositions
    • H10N10/853—Thermoelectric active materials comprising inorganic compositions comprising arsenic, antimony or bismuth

Definitions

  • thermoelectrics specifically an intermetallic compound and a method of manufacture thereof. These materials can utilize a thermal gradient to generate electrical power or can be electrically powered for heating/cooling applications.
  • thermoelectric materials convert heat flow into electrical current and vice versa. Therefore these materials have been sought for the production of electricity from the surroundings, for example, in power station cooling towers to extract energy from the hot exhaust gases.
  • Other practical uses which have been envisioned include nuclear-heated power generating applications for powering spacecraft where solar power is not feasible.
  • the thermoelectric power and, hence, the figure of merit of conventional bulk thermoelectric materials are not currently sufficient for power or space applications.
  • thermoelectric materials could be used to transform heat directly into electrical energy, allowing fuel to be used for power generation more efficiently.
  • Power generators in cars could be made obsolete by utilizing heat from exhaust gases.
  • Thermo-electric waste heat recovery is also applicable to modes of transportation such as diesel-electric locomotives, locomotive diesel engines, automotive diesel engines, diesel-electric hybrid buses, fuel cells, etc.
  • thermoelectric devices have also been viewed as a solution to other environmental problems. Specifically the use of a thermoelectric material to extract heat from a container, for example a refrigerator, removes the requirement for potentially damaging refrigerants. Furthermore, such devices enable new designs of coolers/heaters and air conditioning.
  • thermoelectric materials are particularly favoured for the above applications due to the simplicity of their design.
  • the solid state components are robust and highly reliable with low failure rates.
  • thermoelectric material either in the generation of electrical power, or the creation of a temperature gradient, there are no pollutants released into the atmosphere.
  • thermoelectric materials are scalable and hence ideal for miniature power generation, for example, in thermoelectric micro devices.
  • a thermoelectric cooler will enable temperature control for bio-medical lab-on-chip applications and optoelectronics hundreds of times faster and more precisely than existing technology.
  • Micro thermoelectronic generators will enable self powering microelectonics such as a thermoelectronic wristwatch or, combined with a microcombustor could replace Li-ion batteries in portable electronics. It is hoped that the use of such materials could allow improvements in the reliability of batteries.
  • the present invention aims to overcome or at least mitigate at least some of the problems associated with the prior art.
  • thermoelectric material for thermoelectric applications is determined by its dimensionless figure of merit, ZT.
  • ZT (S 2 ⁇ T)/(k) where S, ⁇ , k and T are the thermo-power (Seebeck coefficient), electrical conductivity, thermal conductivity and temperature respectively.
  • Thermal conductivity ‘k’ is sum of two contributions—electronic (k e ) and lattice (k l ) contributions.
  • a good thermoelectric material has a large ZT value. This large value may result from a large Seebeck coefficient, a high electrical and/or low thermal conductivity.
  • the electronic properties are determined by the power factor, S 2 ⁇ T, which can be optimized by tuning the carrier concentration.
  • ZT may be specified at the temperature at which it is measured.
  • ZT 600K is the thermoelectric dimensionless figure of merit of a material at 600 degrees Kelvin.
  • Binary skutterudites are semiconductors with small band gaps of 100 meV, high carrier mobility, and modest Seebeck coefficients.
  • Binary skutterudite compounds crystallize in a body-centred-cubic structure with space group Im 3 and have the form MX 3 , where M is commonly Fe, Co, Rh or Ir and X is P, As or Sb.
  • M is commonly Fe, Co, Rh or Ir
  • X is P, As or Sb.
  • binary skutterudites have thermal conductivities too high to compete with state-of-the-art thermoelectric materials.
  • filled skutterudites have much lower thermal conductivities. Therefore, filled skutterudites are increasingly popular as a thermoelectric material due to their lower thermal conductivities.
  • Filled skutterudites can be formed by inserting rare earth guest atoms interstitially into large voids in the crystal structure of binary skutterudites.
  • the chemical composition for filled skutterudites can be expressed as Z y M 4 X 12 , where Z represents a guest atom, typically a rare earth atom, and y is its filling fraction.
  • Z represents a guest atom, typically a rare earth atom
  • y is its filling fraction.
  • the lattice thermal conductivities of the rare earth filled skutterudites are significantly reduced over a wide temperature range. As the thermal conductivity due to lattice (k l ) are minimized, ZT is maximized.
  • filled skutterudites This property of filled skutterudites is due to the scattering of heat-carrying low-frequency phonons by the heavy rare earth atoms, which rattle inside the interstitial voids in the skutterudite crystal structure.
  • the filled skutterudites possess attractive electrical transport properties and serve as potential candidates for achieving figure of merit significantly larger than conventional thermoelectric materials.
  • thermoelectric power of these materials can be understood in terms of the phonon glass-electron model.
  • the filler atoms can ‘rattle’ inside the oversized voids in the skutterudite structure.
  • the generation of low frequency phonon modes increases the phonon-phonon scattering which in turn decreases the magnitude of k l .
  • both n- and p-type rare earth filled skutterudites have been reported to have ZT values around 1 above 500° C.
  • One aim of the present invention is to provide a thermoelectric material having a value greater than 1.4 or 1.5 at 600K and to search for novel materials for both cooling and power applications.
  • thermo-power For power and generator applications there is a need for materials and manufacturing techniques which yield high figure of merit, with a large electrical conductivity and low thermal conductivity. It is also desirable that the magnitude of the thermo-power increases with increasing temperature.
  • the present invention provides a method for producing an intermetallic compound, the method comprising:
  • the present invention provides an intermetallic compound exhibiting a ZT 600 k value of ⁇ 0.9 and having the formula:
  • the present invention provides an intermetallic compound obtainable by the process as described herein.
  • FIG. 1 shows the variation of thermoelectric power for (a) Ce 0.85 Fe 4 Sb 12 (b) Ce 0.85 Fe 2.8 Co 1.2 Sb 12 (c) Ce 0.4 Yb 0.53 Fe 2.8 Co 1.2 Sb 12 and (d) annealed Ce 0.4 Yb 0.53 Fe 2.8 Co 1.2 Sb 12 in the temperature range 10-600 K.
  • FIG. 2 shows the variation of thermoelectric power for (a) La 0.85 Fe 4 Sb 12 (b) La 0.85 Fe 2.8 Co 1.2 Sb 12 (c) La 0.4 Yb 0.53 Fe 2.8 Co 1.2 Sb 12 and (d) annealed Ce 0.4 Yb 0.53 Fe 2.8 Co 1.2 Sb 12 in the temperature range 10-600 K.
  • FIG. 3 shows the resistivity against temperature plots of (a) Ce 0.4 Yb 0.53 Fe 4 Sb 12 (b) annealed Ce 0.4 Yb 0.53 Fe 4 Sb 12 (c) Ce 0.4 Yb 0.53 Fe 2.8 Co 1.2 Sb 12 (d) annealed Ce 0.4 Yb 0.53 Fe 2.8 Co 1.2 Sb 12 and (e) annealed La 0.4 M 0.53 Fe 2.8 Co 1.2 Sb n in the temperature range 10-600 K.
  • FIG. 4 shows the figure of merit for several filled skutterudite compositions before and after annealing in Sb vapour.
  • intermetallic compounds may be provided which have improved thermoelectric properties.
  • the method of the present invention produces an intermetallic compound exhibiting a ZT 600 k value of 0.9, more preferably ⁇ 1, ⁇ 1.1, or ⁇ 1.2.
  • the method of the present invention comprises at least three steps. It will, however, be understood that further steps may be incorporated before, between and/or after these three steps.
  • the first step involves providing components A, B and X, wherein A, B and X are:
  • Solid state reaction of components A, B and X provides an intermetallic compound having a filled skutterudite structure and formula of
  • stoichiometric mixtures of the reactants A, B and X are reacted together to form the intermetallic compound of formula A a B b X c .
  • the components A, B and X will be provided as ingots of the elements. Such ingots are readily available commercially. Conventional solid state reaction techniques are well known.
  • the filled skutterudite structure of formula of A a B b X c may be produced, for example, by baking ingots of the elements together in an evacuated container at a suitable time for a suitable duration. The baking is preferably carried out under vacuum or under an inert atmosphere according to conventional methods such as sealing in evacuated glass tubes. The inert atmosphere prevents contamination, oxidation or decomposition of the produced intermetallic. Alternatively, or additionally, unreactive metal tubes may be used.
  • the solid state reaction of A, B and X to form the intermetallic compound having a filled skutterudite structure and a formula of A a B b X c is carried out by heating at a temperature range of from 500° C. to 900° C. for from 1 to 7 days.
  • A is selected from rare earth elements and mixtures of two or more thereof.
  • A is selected from one or more of La, Ce and Yb. Most preferably A is Ce and Yb, or La and Yb.
  • B is selected from one or more of Fe, Co, Rh, Ru, Os and Ir. More preferably B is Fe and Co. B may be Fe.
  • X is selected from C, Si, Ge, Sn, Pb, N, P, As, Sb, Bi, S, Se and Te. More preferably still X is P, As or Sb. Most preferably X is Sb.
  • a is the sum of all A atoms in the intermetallic compound A a B b X c .
  • Advantageously “a” is in the range of from 0.5 to 1, more preferably “a” is in the range of from 0.8 to 1, most preferably “a” is 1.
  • “a” may be in the range 0.81-0.87.
  • “b” is the sum of all B atoms in the intermetallic compound A a B b X c .
  • Preferably “b” is in the range of from 3.8 to 4, most preferably “b” is 4.
  • c is the sum of all X atoms in the intermetallic compound A a B b X c .
  • c is in the range of from 11 to 12.
  • the second step comprises melting the intermetallic compound having a filled skutterudite structure produced in step (1) in the presence of additional X. Melting may be carried using an arc and/or an induction melter. The melting step may be vacuum melting in, for example, a quartz tube.
  • additional X is used herein to mean that the filled skutterudite is melted in the presence of at least some X which has not originated from the filled skutterudite structure.
  • the additional X may optionally be added to the filled skutterudite in the reaction chamber before melting.
  • the third step comprises annealing the filled skutterudite in an X-rich environment at a temperature equal to, or greater than the phase formation temperature of the filled skutterudite.
  • the intermetallic compound is annealed in the presence of additional X.
  • additional X is used herein to mean that the filled skutterudite is annealed in the presence of at least some X which has not originated from the filled skutterudite structure.
  • the additional X may optionally be added to the filled skutterudite in the reaction chamber before annealing.
  • the additional X is the same as the X present in the filled skutterudite structure of formula A a B b X C .
  • X is P, As or Sb. Most preferably X is Sb.
  • annealing it is to be understood that the intermetallic is heated to relieve stresses in the structure.
  • Annealing involves heating to a temperature where diffusion can occur. Maintaining a metal at elevated temperatures reduces dislocation, vacancies, frozen-in stress and other metastable conditions.
  • the first is the recovery phase, which results in softening of the metal through removal of crystal defects and the internal stresses which they cause.
  • the second phase is recrystallization, where new grains nucleate and grow to replace those deformed by internal stresses.
  • a very slow cooling phase is used to induce softness, relieve internal stresses, refine the structure and improve cold working properties. The slow cooling minimises thermal gradients which could re-introduce stress by differential thermal contraction.
  • the process of annealing can allow guest atoms to be incorporated into substitutional positions in the crystal lattice, resulting in drastic changes in the electrical properties of the material.
  • Annealing occurs by the diffusion of atoms within a solid material, so that the material progresses towards its equilibrium state. Heat is needed to increase the rate of diffusion by providing the energy needed to break and form new bonds. The movement of atoms has the effect of redistributing and destroying the dislocations in metals.
  • the amount of process-initiating Gibbs free energy in a deformed metal is also reduced by the annealing process. In practice and industry, this reduction of Gibbs free energy is termed “stress relief.”
  • the relief of internal stresses is a thermodynamically spontaneous process, however, at room temperatures, it is a very slow process. Therefore, the high temperatures at which the annealing process occurs serve to accelerate this slow-albeit-spontaneous process.
  • the step of annealing in an atmosphere rich in X allows the compound to settle in a high temperature phase structure with very few lattice vacancies, these being filled by the excess vapours provided. Whilst not wishing to be bound by particular theory, it appears that this vacancy filing serves to improve the thermoelectric properties of the material. This is surprising as a number of electronic properties of n- and p-type doped semiconductors arise from having vacancies in the lattice structure.
  • the annealing step (3) may also be carried out in the presence of additional A, wherein A is as defined above.
  • the method of the present invention may further comprise a step of pelletising the intermetallic compound provided in step (1) before the melting step (2).
  • the annealing step is performed for a duration greater than 6 hours, 12 hours, 24 hours, more preferably for longer than 72 hours and most preferably for a duration greater than 1 week.
  • Annealing is preferably performed at no less than 50° C. less than the phase formation temperature of the target compound.
  • the phase formation temperature of YbFe 4 Sb 12 for example, is about 650° C.
  • the present inventors have prepared intermetallic compounds exhibiting a ZT 600 k value of 0.9 and having the having the formula:
  • the intermetallic compound has the formula A′B′ 4 X′ 12 , where A′, B′ and X′ are as defined above. It will, however, be understood that the compound may not be of this exact stoichiometric formula, there may be some deficiencies in the number of A′, B′ and/or X′ atoms in the structure of the compound.
  • the intermetallic compound has a filled skutterudite structure (for example, LaFe 4 P 12 ).
  • Antonomides are an example of the filled skutterudite structure. They have a body centred cubic structure with square planar rings of Sb atoms. Metal atoms, for example, iron, form a simple cubic sub-lattice and the guest atoms occupy the two remaining holes in the unit cell.
  • A′ is selected from at least two rare earth elements and mixtures of three or more thereof. More preferably, A′ is selected from two or more of La, Ce and Yb. Most preferably A′ is Ce and Yb, or La and Yb.
  • B′ is preferably one or more of Fe, Co, Rh, Ru, Os and Ir. More preferably, A′ is Fe and Co. More preferably still, A′ is Fe.
  • X′ is selected from C, Si, Ge, Sn, Pb, N, P, As, Sb, Bi, S, Se, and Te. More preferably X is P, As or Sb. Most preferably X′ is Sb.
  • a′ is the sum of all A′ atoms in the intermetallic compound.
  • a′ is in the range of from 0.5 to 1, more preferably “a′” is in the range of from 0.8 to 1 , most preferably “a′” is 1.
  • a′ may be in the range 0.81-0.87.
  • b′ is the sum of all B atoms in the intermetallic compound.
  • b′ is in the range of from 3.8 to 4, most preferably “b′” is 4.
  • c′ is the sum of all X′ atoms in the intermetallic compound. Preferably “c′” is in the range of from 11 to 12.
  • the intermetallic compound as described herein shows improved thermoelectric properties over prior art compounds.
  • the intermetallic compounds have high dimensionless figure of merit (ZT) values.
  • ZT dimensionless figure of merit
  • the intermetallic compound as described herein exhibits a ZT 600 k value of ⁇ 1, more preferably ZT 600 k value of ⁇ 1.1, more preferably still ZT 600 k value of ⁇ 1.2.
  • A′ is Ce and Yb
  • B′ is Fe
  • X′ is Sb
  • the intermetallic compound may have the formula Ce 0.4 Yb 0.53 Fe 4 Sb 12 .
  • A′ is La and Yb
  • B′ is Fe
  • X′ is Sb
  • the intermetallic compound may have the formula La 0.4 Yb 0.53 Fe 4 Sb 12 .
  • A′ is La and Yb
  • B′ is Fe and Co
  • X′ is Sb
  • the intermetallic compound may have the formula La 0.4 Yb 0.53 Fe 2.8 Co 1.2 Sb 12 .
  • A′ is Ce and Yb, or A′ is Ce and La, B′ is Fe and Co and X′ is Sb.
  • intermetallic compounds having the formulas Ce 0.4 Yb 0.53 Fe 2.8 Co 1.2 Sb 12 and Ce 0.4 Yb 0.53 Fe 2.8 Co 1.2 Sb 12 have been shown to have particularly high dimensionless figure of merit values, which may be up to or greater than 1.2.
  • the present inventors have found that substitution of Co at Fe sites in the filled skutterudite structure has been found to advantageously increase the figure of merit value. Cobalt also has the advantage that it is a cheap material for doping the filled skutterudite.
  • B′ is Fe and Co.
  • a film comprising the intermetallic compound as described herein.
  • the film may be a thin film, having a diameter of from 10 nm to 10 micron, or from 10 nm to 1 micron.
  • the film may be made using standard techniques known in the art, for example sputtering techniques or pulse laser deposition.
  • the intermetallic compound as described herein may be deposited onto a substrate.
  • the substrate may be, for example a metal, alloy, and/or a ceramic.
  • a wafer comprising the intermetallic compound as described herein.
  • a peltier cooler comprising an intermetallic compound as described herein.
  • thermoelectric generator comprising an intermetallic compound as described herein.
  • thermoelectric material in a further aspect of the present invention there is provided the use of an intermetallic compound as described herein as a thermoelectric material.
  • a peltier cooler/heater device comprising an intermetallic filled skutterudite compound as described above will have a high efficiency in converting inputted electricity to creating a large temperature gradient within the device.
  • a thermoelectric generator comprising a filled skutterudite compound according to the present invention will have a high efficiency in producing electricity from a provided temperature gradient.
  • a magnetoresistor comprising an intermetallic compound as described herein.
  • thermoelectric materials of the present invention When the thermoelectric materials of the present invention are employed in magnetoresistors they are found to exhibit improved temperature stability of the magnetoresistance over an extended temperature range.
  • a multilayer comprising a first electrode, a second electrode, and an interlayer there between, said interlayer comprising an intermetallic compound as described herein.
  • the compounds Z 1-x Yb x Fe 4 Sb 12 and Z 1-x Yb x Fe 3.9 Co 0.01 Sb 12 were synthesized from high purity starting ingots of La, Ce, Yb, Fe, Co and Sb purchased from Sigma Aldrich. Stoichiometric mixtures of these reactants were then sealed in evacuated ( ⁇ 10 ⁇ 6 mbar) quartz tubes. The samples were then heated very slowly with a ramp of 0.5°/min to 400° C. The samples were kept at this temperature for 48 hours. The temperature was then raised to 700° C. for one week. Finally the samples were quenched to room temperature.
  • thermoelectric power measurements the samples were cut into bar-shaped samples by a diamond wheel. These bar-shaped sample were clamped between a heater and a copper block which acted as a heat sink and incorporated the thermometers and connections. The heater was pressed against the sample by springs. Discs of gold (foils) were fixed with electrically insulating and thermally conducting epoxy on top of the heater and on the bottom of the copper block to ensure a homogeneous lateral temperature and an electrical insulation of the sample. Two Chromel/Constantan thermocouples measured the steady thermal gradient ( ⁇ T, typically 1 K) established across the sample and the voltage (thermoelectric voltage) was measured. Resistivity measurements were carried by standard van der Pauw four probe method.
  • FIGS. 1&2 illustrate the Seebeck coefficient of compounds (Ce,Yb)Fe 4 Sb 12 and (La,Yb)Fe 4 Sb 12 in the temperature range 10-600 K. It can be noted that Seebeck coefficient increases with temperature up to 600 K for all compositions.
  • Resistivity plots of (Ce,Yb)Fe 4 Sb 12 and (La,Yb)Fe 4 Sb 12 are shown in FIG. 3 .
  • the resistivity of all of the compounds indicated metallic behaviour.
  • Room temperature resistivity decreased with Yb doping in both series, as shown in Table I and FIG. 3 .
  • the linear variation of resistivity as a function of temperature can be explained by the semi-metallic behaviour found in Fe-rich filled skutterudites.
  • FIG. 4 shows the calculated dimensionless figure of merit for Ce 0.4 Yb 0.53 Fe 4 Sb 12 and Ce 0.4 Yb 0.53 Fe 2.8 Co 1.2 Sb 12 before and after annealing.
  • the figure of merit of annealed Ce 0.4 Yb 0.53 Fe 4 Sb 12 reaches 0.48 and 1.1 at 300 K and 600 K respectively.
  • Table I summarizes the values of resistivity values ( ⁇ ) (values in brackets correspond to 600 K), Seebeck coefficient (S), thermal conductivity ( ⁇ ) and figure of merit ZT at 300 K and 600 K for (Ce,Yb)Fe 4 Sb 12 and (La,Yb)Fe 4 Sb 12 and related compounds.
  • thermoelectric power of (Ce,Yb)Fe 4 Sb 12 and (La,Yb)Fe 4 Sb 12 filled skutterudites The role of the filler atoms and annealing treatment has been investigated in the thermoelectric power of (Ce,Yb)Fe 4 Sb 12 and (La,Yb)Fe 4 Sb 12 filled skutterudites. Dimensionless figure of merit increases dramatically upon annealing in Sb atmosphere. Annealing in an Sb-rich atmosphere increases the thermoelectric power and reduces the thermal conductivity. This provides a path for enhancing the dimensionless figure of merit in these materials by simultaneous void filling and optimized annealing. The results of these materials show promising features for future microelectronic applications.

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GBGB0724752.1A GB0724752D0 (en) 2007-12-19 2007-12-19 Method for producing a thermoelectric material
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PCT/GB2008/004209 WO2009077767A1 (en) 2007-12-19 2008-12-19 Method for producing a thermoelectric intermetallic compound

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