IP Library › Granted Patent US 12,707,893
Granted Patent B2
US 12,707,893 · App. 19/038,444 · Granted Aug 11, 2026

Aerosol jet printing and sintering of thermoelectric devices

Inventors: Yanliang Zhang (South Bend, IN); Mortaza Saeidi-Javash (South Bend, IN)
Assignee: UNIVERSITY OF NOTRE DAME DU LAC
H10N10/852C09D7/61C09D7/66C09D11/322C09D11/36C09D11/38C09D11/52H10N10/01
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Quick Facts
Patent No.
US 12,707,893
App. No.
19/038,444
Granted
Aug 11, 2026
Kind
B2
Abstract

Methods, ink compositions, and 3D conformal printed flexible films. The method may include aerosol jet printing a thermoelectric ink composition, followed by photonic or other sintering of the ink to remove surfactant included therein, and to convert the thermoelectric nanoparticles of the ink composition into a dense structure capable of charge carrier transport. The ink compositions may be solution-processed semimetal-chalcogenides (e.g., Te containing materials) in a suitable carrier (e.g., polyol(s), alcohol(s), etc.). A surfactant (e.g., PVP) may be present. Within seconds of photonic sintering, the electrical conductivity of the printed film is dramatically increased from non-conductive to a value on the order of at least 1×10 4 S/m. The films may demonstrate a room-temperature power factor of at least 500 μWm −1 K −2 . The realized values of 730-2200 μWm −1 K −2 achieved are among the highest values reported for flexible thermoelectric films. The film is durable (e.g., 500 bending cycles with no significant performance drop).

Claims (38)

1 . An aerosol jet printable ink composition comprising:

a carrier including:

a first polyol, and

a second polyol, the second polyol being different from the first polyol;

thermoelectric nanoparticles, nanoplates, or nanorods dispersed in the carrier; and

a surfactant for preventing or minimizing agglomeration of the nanoparticles, nanoplates, or nanorods wherein the first polyol and the second polyol are present at a weight ratio of from about 2:1 to about 10:1.

2 . A method for producing a thermoelectric device, the method comprising:

providing an aerosol jet printable ink composition including thermoelectric nanoparticles, nanoplates and/or nanorods and a surfactant in a carrier, wherein the carrier includes a first polyol and a second polyol, and wherein the first polyol and the second polyol are present at a weight ratio of from about 2:1 to about 10:1;

printing the aerosol jet printable ink composition onto a substrate to provide a desired pattern thereon; and

sintering the printed aerosol jet printable ink composition to remove the surfactant and convert the thermoelectric nanoparticles, nanoplates and/or nanorods into a dense structure capable of charge carrier transport,

wherein the process is carried out at ambient temperature so that any heating of the substrate is minimal.

3 . A method as recited in claim 2 , wherein sintering of the printed aerosol jet printable ink composition comprises photonic or thermal sintering.

4 . A method as recited in claim 2 , wherein the thermoelectric nanoparticles, nanoplates and/or nanorods comprise a chalcogenide.

5 . A method as recited in claim 4 , wherein the chalcogenide comprises Te.

6 . A method as recited in claim 2 , wherein the thermoelectric nanoparticles, nanoplates and/or nanorods comprise a thermoelectric material comprising Bi, Te, and Se, or a thermoelectric material comprising Sb and Te.

7 . A method as recited in claim 2 , wherein the thermoelectric nanoparticles, nanoplates and/or nanorods comprise at least one of Bi 2 Te 2.7 Se 0.3 or Sb 2 Te 3 .

8 . A method as recited in claim 2 , wherein the thermoelectric nanoparticles, nanoplates and/or nanorods comprise an Sb 2 Te 3 —Te composite including Sb 2 Te 3 nanoplates and Te nanorods.

9 . A method as recited in claim 2 , wherein the carrier comprises a lower alcohol having 1-4 carbon atoms, wherein the polyols comprise from 20-60% by weight of the carrier, and the lower alcohol comprises from 40-80% by weight of the carrier.

10 . A method as recited in claim 2 , wherein the sintering is photonic sintering, and is performed using intense pulsed light (IPL).

11 . A method as recited in claim 2 , wherein the sintering is photonic sintering and is completed within less than 30 minutes, less than 20 minutes, less than 10 minutes, less than 5 minutes, less than 1 minute, less than 30 seconds, less than 10 seconds, or less than 5 seconds.

12 . A method as recited in claim 2 , wherein the sintering is photonic sintering and is performed using intense pulsed light (IPL) with a pulse duration from 1 ms to 10 ms, from 1.5 ms to 5 ms, or from 1.5 ms to 3 ms.

13 . A method as recited in claim 2 , wherein the sintering is photonic sintering and is performed using intense pulsed light (IPL) with a power density from 1 kW/cm 2 to 10 kW/cm 2 , from 2 kW/cm 2 to 8 kW/cm 2 or from 3 kW/cm 2 to 6 kW/cm 2 .

14 . A method as recited in claim 2 , wherein the sintering is photonic sintering and is performed using intense pulsed light (IPL) with a pulse delay from 100 to 3000 ms, from 200 to 2000 ms, or from 300 to 1000 ms between adjacent photonic pulses.

15 . A method as recited in claim 2 , wherein the sintering is photonic sintering and is performed using intense pulsed light (IPL) within no more than 10 s, no more than 8 s, no more than 5s, no more than 3 s, or no more than 2 s.

16 . A method as recited in claim 2 , wherein the substrate has a melting temperature of less than 400° C.

17 . A method as recited in claim 2 , wherein the substrate includes a curved surface to which the ink composition is applied.

18 . A method as recited in claim 2 , wherein the substrate is at least one of cellulose-based, polymer-based, glass, or other ceramic.

19 . A method as recited in claim 2 , wherein the method is used to produce a multi-layered structure.

20 . A method as recited in claim 19 , wherein each layer of the produced multi-layered structure has a thickness of from about 10 μm to about 1000 μm.

21 . A conformal thermoelectric film comprising:

a matrix of thermoelectric nanoparticles, nanoplates and/or nanorods configured as a flexible conformal thermoelectric film;

wherein the thermoelectric film has a power factor of at least 500 μWm −1 K −2 at room temperature;

wherein the matrix of thermoelectric nanoparticles comprises Sb 2 Te 3 nanoplates and Te nanorods.

22 . A method for producing a thermoelectric device, the method comprising:

providing an aerosol jet printable ink composition including thermoelectric nanoparticles, nanoplates and/or nanorods and a surfactant in a carrier, wherein the thermoelectric nanoparticles, nanoplates and/or nanorods comprise an Sb 2 Te 3 —Te composite including Sb 2 Te 3 nanoplates and Te nanorods;

printing the aerosol jet printable ink composition onto a substrate to provide a desired pattern thereon; and

sintering the printed aerosol jet printable ink composition to remove the surfactant and convert the thermoelectric nanoparticles, nanoplates and/or nanorods into a dense structure capable of charge carrier transport,

wherein the process is carried out at ambient temperature so that any heating of the substrate is minimal.

Assignments (1)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Feb 1, 2025
From: ZHANG, YANLIANG; SAEIDI-JAVASH, MORTAZA
To: UNIVERSITY OF NOTRE DAME DU LAC
Reel/Frame 070082/0648 →
Continuity (5)
Continuation 17609159 · Jun 8, 2020
Provisional Application 62887845 · Aug 16, 2019
Provisional Application 62862515 · Jun 17, 2019
Provisional Application 62858848 · Jun 7, 2019
Related Publication 20250194422A1 · Jun 12, 2025
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