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Tian Y, Florenciano I, Xia H, Li Q, Baysal HE, Zhu D, Ramunni E, Meyers S, Yu TY, Baert K, Hauffman T, Nider S, Göksel B, Molina-Lopez F. Facile Fabrication of Flexible and High-Performing Thermoelectrics by Direct Laser Printing on Plastic Foil. ADVANCED MATERIALS (DEERFIELD BEACH, FLA.) 2024; 36:e2307945. [PMID: 38100238 DOI: 10.1002/adma.202307945] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 08/07/2023] [Revised: 11/30/2023] [Indexed: 12/23/2023]
Abstract
The emerging fields of wearables and the Internet of Things introduce the need for electronics and power sources with unconventional form factors: large area, customizable shape, and flexibility. Thermoelectric (TE) generators can power those systems by converting abundant waste heat into electricity, whereas the versatility of additive manufacturing suits heterogeneous form factors. Here, additive manufacturing of high-performing flexible TEs is proposed. Maskless and large-area patterning of Bi2Te3-based films is performed by laser powder bed fusion directly on plastic foil. Mechanical interlocking allows simultaneous patterning, sintering, and attachment of the films to the substrate without using organic binders that jeopardize the final performance. Material waste could be minimized by recycling the unexposed powder. The particular microstructure of the laser-printed material renders the-otherwise brittle-Bi2Te3 films highly flexible despite their high thickness. The films survive 500 extreme-bending cycles to a 0.76 mm radius. Power factors above 1500 µW m-1K-2 and a record-low sheet resistance for flexible TEs of 0.4 Ω sq-1 are achieved, leading to unprecedented potential for power generation. This versatile fabrication route enables innovative implementations, such as cuttable arrays adapting to specific applications in self-powered sensing, and energy harvesting from unusual scenarios like human skin and curved hot surfaces.
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Affiliation(s)
- Yuan Tian
- KU Leuven, Department of Materials Engineering, Kasteelpark Arenberg 44 - bus 2450, Leuven, 3001, Belgium
| | - Isidro Florenciano
- KU Leuven, Department of Materials Engineering, Kasteelpark Arenberg 44 - bus 2450, Leuven, 3001, Belgium
| | - Heyi Xia
- KU Leuven, Department of Materials Engineering, Kasteelpark Arenberg 44 - bus 2450, Leuven, 3001, Belgium
| | - Qiyuan Li
- KU Leuven, Department of Materials Engineering, Kasteelpark Arenberg 44 - bus 2450, Leuven, 3001, Belgium
| | - Hasan Emre Baysal
- KU Leuven, Department of Materials Engineering, Kasteelpark Arenberg 44 - bus 2450, Leuven, 3001, Belgium
| | - Daiman Zhu
- KU Leuven, Department of Materials Engineering, Kasteelpark Arenberg 44 - bus 2450, Leuven, 3001, Belgium
| | - Eduardo Ramunni
- KU Leuven, Department of Materials Engineering, Kasteelpark Arenberg 44 - bus 2450, Leuven, 3001, Belgium
| | - Sebastian Meyers
- KU Leuven, Department of Mechanical Engineering, Celestijnenlaan 300 - bus 2420, Leuven, 3001, Belgium
| | - Tzu-Yi Yu
- KU Leuven, Department of Materials Engineering, Kasteelpark Arenberg 44 - bus 2450, Leuven, 3001, Belgium
| | - Kitty Baert
- Vrije Universiteit Brussel, Department of Materials and Chemistry, Research Group Sustainable Materials Engineering (SUME), Lab Electrochemical and Surface Engineering (SURF), Pleinlaan 2, Brussels, 1050, Belgium
| | - Tom Hauffman
- Vrije Universiteit Brussel, Department of Materials and Chemistry, Research Group Sustainable Materials Engineering (SUME), Lab Electrochemical and Surface Engineering (SURF), Pleinlaan 2, Brussels, 1050, Belgium
| | - Souhaila Nider
- KU Leuven, Department of Chemical Engineering, Celestijnenlaan 200J - bus 2424, Leuven, 3001, Belgium
| | - Berfu Göksel
- KU Leuven, Department of Materials Engineering, Kasteelpark Arenberg 44 - bus 2450, Leuven, 3001, Belgium
| | - Francisco Molina-Lopez
- KU Leuven, Department of Materials Engineering, Kasteelpark Arenberg 44 - bus 2450, Leuven, 3001, Belgium
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Additive Manufacturing of Bulk Thermoelectric Architectures: A Review. ENERGIES 2022. [DOI: 10.3390/en15093121] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 12/04/2022]
Abstract
Additive manufacturing offers several opportunities for thermoelectric energy harvesting systems. This new manufacturing approach enables customized leg geometries, minimized thermal boundary resistances, less retooling, reduced thermoelectric material waste, and strong potential to manipulate microstructure for higher values of figure of merit. Although additive manufacturing has been used to fabricate thin thermoelectric films, there has been comparatively limited demonstrations of additive manufacturing for bulk thermoelectric structures. This review provides insights about the current progress of bulk thermoelectric material and device additive manufacturing. Each additive manufacturing technique used to produce bulk thermoelectric structures is discussed in detail along with future directions and challenges.
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