WO2016054333A1 - Thermoelectric generating unit and methods of making and using same - Google Patents
Thermoelectric generating unit and methods of making and using same Download PDFInfo
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- WO2016054333A1 WO2016054333A1 PCT/US2015/053434 US2015053434W WO2016054333A1 WO 2016054333 A1 WO2016054333 A1 WO 2016054333A1 US 2015053434 W US2015053434 W US 2015053434W WO 2016054333 A1 WO2016054333 A1 WO 2016054333A1
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- thermoelectric
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- thermoelectric devices
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- side plate
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L23/00—Details of semiconductor or other solid state devices
- H01L23/34—Arrangements for cooling, heating, ventilating or temperature compensation ; Temperature sensing arrangements
- H01L23/46—Arrangements for cooling, heating, ventilating or temperature compensation ; Temperature sensing arrangements involving the transfer of heat by flowing fluids
- H01L23/473—Arrangements for cooling, heating, ventilating or temperature compensation ; Temperature sensing arrangements involving the transfer of heat by flowing fluids by flowing liquids
-
- 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
- H10N10/01—Manufacture or treatment
-
- 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
- H10N10/10—Thermoelectric devices comprising a junction of dissimilar materials, i.e. devices exhibiting Seebeck or Peltier effects operating with only the Peltier or Seebeck effects
- H10N10/13—Thermoelectric devices comprising a junction of dissimilar materials, i.e. devices exhibiting Seebeck or Peltier effects operating with only the Peltier or Seebeck effects characterised by the heat-exchanging means at the junction
-
- 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
- H10N10/10—Thermoelectric devices comprising a junction of dissimilar materials, i.e. devices exhibiting Seebeck or Peltier effects operating with only the Peltier or Seebeck effects
- H10N10/17—Thermoelectric devices comprising a junction of dissimilar materials, i.e. devices exhibiting Seebeck or Peltier effects operating with only the Peltier or Seebeck effects characterised by the structure or configuration of the cell or thermocouple forming the device
-
- 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
- H10N10/852—Thermoelectric active materials comprising inorganic compositions comprising tellurium, selenium or sulfur
-
- 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
- thermoelectric generating units This present application is directed to thermoelectric generating units. It would be recognized that the invention has a much broader range of applicability.
- Thermoelectric (TE) devices are often packaged using a plurality of
- thermoelectric legs arranged in multiple serial chain configurations on a base structure.
- Each of the plurality of thermoelectric legs can include either p-type or n-type thermoelectric material, which can be characterized by high electrical conductivity and relatively high thermal resistivity.
- One or more p-type TE legs can be pairwise-coupled to one or more n- type TE legs via a conductor from each direction in a serial chain or electrically in series- thermally in parallel or electrically in parallel-thermally in parallel configuration, one conductor being coupled at one end region of the TE leg and another conductor being coupled at another end region of the TE leg.
- thermoelectric device When a bias voltage is applied across the top/bottom regions of the thermoelectric device using the two conductors as two electrodes, a temperature difference is generated so that the thermoelectric device can be used as a refrigeration (e.g., Peltier) device.
- a refrigeration e.g., Peltier
- the thermoelectric device is subjected to a thermal junction with conductors at first end regions of the TE legs being attached to a cold side of the junction and conductors at second end regions of the TE legs being in contact with a hot side of the junction, the thermoelectric device is able to generate electrical voltage across the junction as an energy conversion (e.g., Seebeck) device.
- energy conversion e.g., Seebeck
- thermoelectric figure of merit ZT
- TS 2 ⁇ /k T is the temperature
- S the Seebeck coefficient
- crthe electrical conductivity the thermal conductivity of the thermoelectric material
- thermoelectric generating units This present application is directed to thermoelectric generating units. It would be recognized that the invention has a much broader range of applicability.
- a thermoelectric generating unit includes a hot-side heat exchanger including a first side, a second side, and one or more discrete channels; a substantially flat first cold-side plate; and a substantially flat second cold-side plate.
- the thermoelectric generating unit further can include a first plurality of thermoelectric devices arranged between the first cold-side plate and the first side of the hot-side heat exchanger; and a second plurality of thermoelectric devices arranged between the second cold-side plate and the second side of the hot-side heat exchanger.
- the thermoelectric generating unit further can include a plurality of fasteners extending between the first cold-side plate and the second cold-side plate at respective locations outside of the one or more discrete channels of the hot-side heat exchanger.
- the fasteners can be disposed within gaps between the thermoelectric devices of the first plurality and within gaps between the thermoelectric devices of the second plurality.
- the fasteners can compress the first plurality of thermoelectric devices between the first cold-side plate and the first side of the hot-side heat exchanger and compressing the second plurality of thermoelectric devices between the second cold-side plate and the second side of the hot-side heat exchanger.
- a first subset of the first plurality of thermoelectric devices is centrally disposed and a second subset of the first plurality of thermoelectric devices is peripherally disposed.
- a first subset of the plurality of fasteners can apply a first force to the first subset of the first plurality of thermoelectric devices.
- a second subset of the plurality of fasteners can apply a second force to the second subset of the first plurality of thermoelectric devices.
- the first force can be greater than the second force.
- the first force is at least 1.5 times the second force.
- a third subset of the first plurality of thermoelectric devices is disposed between the first subset of the first plurality of thermoelectric devices and the third subset of the first plurality of thermoelectric devices.
- a third subset of the plurality of fasteners can apply a third force to the third subset of the first plurality of thermoelectric devices.
- the third force can be less than the first force and greater than the second force.
- the first force is about 1.5 times the third force, and the first force is about 3 times the second force.
- the first force can be about 11-13 kN, the third force is about 7-9 kN, and the second force is about 3-5 kN.
- each fastener includes a bolt or screw; and a spring, a Belleville washer, or a spring washer disposed along the bolt or screw.
- a first subset of the plurality of fasteners includes a greater number of springs, Belleville washers, or spring washers disposed along the bolts or screws of that subset than does a second subset of the plurality of fasteners.
- the first plurality of thermoelectric devices is arranged in columns and rows between the first cold-side plate and the first side of the hot-side heat exchanger, the fasteners respectively being disposed within gaps between the columns and rows.
- Some embodiments include four fasteners for every four thermoelectric devices of the first plurality of thermoelectric devices and for every four thermoelectric devices of the second plurality of thermoelectric devices.
- the hot-side heat exchanger further includes fins disposed within each of the one or more discrete channels.
- the fins include stainless steel, nickel plated copper, or stainless steel clad copper.
- a density of the fins within each of the one or more discrete channels is at least 12 fins per inch.
- the hot-side heat exchanger includes at least one threaded rod configured to sealingly couple the hot-side heat exchanger to a pipe flange.
- the first cold-side plate further includes pin fins, straight fins, or offset fins.
- the pin fins are arranged in an in-line arrangement or in a staggered arrangement.
- the first plurality of thermoelectric devices is disposed on a circuit board.
- the first plurality of thermoelectric devices include a thermoelectric material, the thermoelectric material being selected from the group consisting of: tetrahedrite, magnesium silicide, magnesium silicide stannide, silicon, silicon nanowire, bismuth telluride, skutterudite, lead telluride, TAGS (tellurium-antimony-germanium-silver), zinc antimonide, silicon germanium, and a half-Heusler compound.
- the thermoelectric material being selected from the group consisting of: tetrahedrite, magnesium silicide, magnesium silicide stannide, silicon, silicon nanowire, bismuth telluride, skutterudite, lead telluride, TAGS (tellurium-antimony-germanium-silver), zinc antimonide, silicon germanium, and a half-Heusler compound.
- At least one of the first cold-side plate and the second cold- side plate includes a high efficiency cold-side heat exchanger; and the hot-side heat exchanger includes a high efficiency hot-side heat exchanger.
- the first cold-side plate includes an inlet for coolant inflow and an outlet for coolant outflow, wherein the inlet and outlet are on the same side of the first cold-side plate as one another.
- Some embodiments include at least one of the following: a kapton film disposed between the first side of the hot-side heat exchanger and at least one thermoelectric device of the first plurality of thermoelectric devices; a kapton film disposed between the first cold-side plate and at least one thermoelectric device of the first plurality of thermoelectric devices; a mica sheet disposed between the first side of the hot-side heat exchanger and at least one thermoelectric device of the first plurality of thermoelectric devices; a graphite sheet disposed between the first side of the hot-side heat exchanger and at least one thermoelectric device of the first plurality of thermoelectric devices; a gap pad disposed between the first cold-side plate and at least one thermoelectric device of the first plurality of thermoelectric devices; and an anodized layer disposed between the first cold-side plate and at least one thermoelectric device of the first plurality of thermoelectric devices.
- a method of assembling a thermoelectric generating unit includes providing a hot-side heat exchanger including a first side, a second side, and one or more discrete channels; providing a substantially flat first cold-side plate; and providing a substantially flat second cold-side plate.
- the method can include arranging a first plurality of thermoelectric devices between the first cold-side plate and the first side of the hot-side heat exchanger and arranging a second plurality of thermoelectric arranged between the second cold-side plate and the second side of the hot-side heat exchanger.
- the method also can include disposing a plurality of fasteners extending between the first cold-side plate and the second cold-side plate at respective locations outside of the one or more discrete channels of the hot-side heat exchanger and within gaps between the thermoelectric devices of the first plurality and within gaps between the thermoelectric devices of the second plurality.
- the method also can include compressing by the fasteners the first plurality of thermoelectric devices between the first cold-side plate and the first side of the hot-side heat exchanger and the second plurality of thermoelectric devices between the second cold-side plate and the second side of the hot-side heat exchanger.
- the method further can include centrally disposing a first subset of the first plurality of thermoelectric devices; peripherally disposing a second subset of the first plurality of thermoelectric devices; applying a first force to the first subset of the first plurality of thermoelectric devices with a first subset of the plurality of fasteners; and applying a second force to the second subset of the first plurality of thermoelectric devices with a second subset of the plurality of fasteners.
- the first force can be greater than the second force.
- the first force can be at least 1.5 times the second force.
- the method further can include disposing a third subset of the first plurality of thermoelectric devices is between the first subset of the first plurality of thermoelectric devices and the third subset of the first plurality of thermoelectric devices; and applying a third force to the third subset of the first plurality of thermoelectric devices with a third subset of the plurality of fasteners.
- the third force can be less than the first force and greater than the second force.
- the first force is about 1.5 times the third force, and the first force is about 3 times the second force.
- the first force is about 11-13 kN
- the third force is about 7-9 kN
- the second force is about 3-5 kN.
- each fastener includes a bolt or screw; and a spring, a Belleville washer, or a spring washer disposed along the bolt or screw.
- a first subset of the plurality of fasteners includes a greater number of springs, Belleville washers, or spring washers disposed along the bolts or screws of that subset than does a second subset of the plurality of fasteners.
- the method further includes arranging the first plurality of thermoelectric devices in columns and rows between the first cold-side plate and the first side of the hot-side heat exchanger; and respectively disposing the fasteners within gaps between the columns and rows. Some embodiments include disposing four fasteners for every four thermoelectric devices.
- the hot-side heat exchanger further includes fins disposed within each of the one or more discrete channels.
- the fins include stainless steel, nickel plated copper, or stainless steel clad copper.
- a density of the fins within each of the one or more discrete channels is at least 12 fins per inch.
- the hot-side heat exchanger includes at least one threaded rod
- the method further includes sealingly coupling the hot-side heat exchanger to a pipe flange via the at least one threaded rod.
- the first cold-side plate further includes pin fins, straight fins, or offset fins.
- the pin fins are arranged in an in-line arrangement or in a staggered arrangement, or include brazed offset pin fins.
- the method further includes disposing the first plurality of thermoelectric devices on a circuit board.
- the first plurality of thermoelectric devices include a thermoelectric material, the thermoelectric material being selected from the group consisting of: tetrahedrite, magnesium silicide, magnesium silicide stannide, silicon, silicon nanowire, bismuth telluride, skutterudite, lead telluride, TAGS (tellurium-antimony-germanium-silver), zinc antimonide, silicon germanium, and a half-Heusler compound.
- the thermoelectric material being selected from the group consisting of: tetrahedrite, magnesium silicide, magnesium silicide stannide, silicon, silicon nanowire, bismuth telluride, skutterudite, lead telluride, TAGS (tellurium-antimony-germanium-silver), zinc antimonide, silicon germanium, and a half-Heusler compound.
- At least one of the first cold-side plate and the second cold- side plate includes a high efficiency cold-side heat exchanger; and the hot-side heat exchanger includes a high efficiency hot-side heat exchanger.
- the first cold-side plate includes an inlet for coolant inflow and an outlet for coolant outfiow, wherein the inlet and outlet are on the same side of the first cold-side plate as one another.
- the method includes at least one of the following:
- thermoelectric device of the first plurality of thermoelectric devices disposing a kapton film between the first side of the hot-side heat exchanger and at least one thermoelectric device of the first plurality of thermoelectric devices; disposing a kapton film between the first cold-side plate and at least one thermoelectric device of the first plurality of thermoelectric devices; disposing a mica sheet between the first side of the hot-side heat exchanger and at least one thermoelectric device of the first plurality of thermoelectric devices; disposing a graphite sheet between the first side of the hot-side heat exchanger and at least one thermoelectric device of the first plurality of thermoelectric devices; disposing a gap pad between the first cold-side plate and at least one thermoelectric device of the first plurality of thermoelectric devices; and disposing an anodized layer between the first cold- side plate and at least one thermoelectric device of the first plurality of thermoelectric devices.
- FIGS. 1 A-1G schematically illustrate views of an exemplary thermoelectric generating unit, according to some embodiments.
- FIGS. 2A-2C schematically illustrate views of an exemplary thermoelectric assembly for use in a thermoelectric generating unit such as illustrated in FIGS. 1A-1G, according to some embodiments.
- FIGS. 3A-3C schematically illustrate exemplary arrangements of fasteners for use in a thermoelectric generating unit such as illustrated in FIGS. 1A-1G, according to some embodiments.
- FIG. 4A schematically illustrates one nonlimiting example of an arrangement of fasteners for use in a thermoelectric generating unit such as illustrated in FIGS. 1A-1G, according to some embodiments.
- FIG. 4B schematically illustrates one nonlimiting example of a distribution of pressures that can be obtained using the arrangement of fasteners illustrated in FIG. 4A.
- FIG. 5 illustrates a plot of exemplary power output as a function of exhaust flow for a thermoelectric generating unit such as illustrated in FIGS. 1A-1G, according to some embodiments.
- FIG. 6 illustrates a plot of exemplary pressure drop as a function of exhaust flow for a thermoelectric generating unit such as illustrated in FIGS. 1A-1G, according to some embodiments.
- FIG. 7 schematically illustrates steps in an exemplary method of preparing a thermoelectric generating unit, according to some embodiments.
- thermoelectric generating units This present application is directed to thermoelectric generating units. It would be recognized that the invention has a much broader range of applicability.
- thermoelectric generating units can include a plurality of thermoelectric devices that are provided in a sandwich-type
- thermoelectric devices can be disposed between one side of the hot-side heat exchanger and one of the cold-side plates, and some of the thermoelectric devices can be disposed between the other side of the hot-side heat exchanger and the other cold-side plate. So as to provide for sufficient thermal contact between the thermoelectric devices, the hot-side heat exchanger, and the respective cold-side plates throughout a range of operating temperatures while inhibiting leakage of the fluid carrying waste heat, a plurality of fasteners can be distributed across and can compress the sandwich-type arrangement.
- the hot-side heat exchanger can include one or more discrete channels, e.g., multiple discrete channels, through which the fluid carrying waste heat can flow, and the fasteners can be arranged outside of the one or more discrete channels, e.g., within gaps between the channels, rather than being disposed through one of the channels, so as to inhibit potential leakage of the fluid out of the hot-side heat exchanger within the thermoelectric generating unit.
- the fasteners can be disposed within gaps between the thermoelectric devices.
- the cold-side plates can be substantially flat, so that the pressure imposed by the fasteners onto the thermoelectric devices can be relatively even across the thermoelectric generating unit at operating temperature.
- FIGS. 1 A-1G schematically illustrate views of an exemplary thermoelectric generating unit (TGU), according to some embodiments.
- the non-limiting embodiment of TGU 100 illustrated in FIGS. 1A-1G includes first cold-side plate 110, hot side heat exchanger 120, second cold-side plate 130, first thermoelectric assembly 160, second thermoelectric assembly 170, and a plurality of fasteners 111.
- first thermoelectric assembly 160 can be disposed between first cold-side plate 110 and first side 126 of hot-side heat exchanger 120
- second thermoelectric assembly 170 can be disposed between second cold-side plate 120 and second side 127 of hot-side heat exchanger 120.
- Fasteners 111 can be disposed through holes that are defined through first cold-side plate 110, hot side heat exchanger 120, second cold-side plate 130, first thermoelectric assembly 160, and second thermoelectric assembly 170, and can provide a suitable distribution of forces and pressures over the TGU so as to maintain satisfactory thermal contact between components of the TGU under a variety of operating conditions that can cause different thermal expansions of such components.
- hot-side heat exchanger 120 includes first side 126, second side 127, and one or more discrete channels, e.g., a plurality of discrete channels 121.
- Each of the one or more discrete channels 121 can be configured so as to receive fluid carrying waste heat, e.g., exhaust from an engine.
- each of the one or more discrete channels 121 can include a fluidic inlet 123 and a fluidic outlet 128 and a lumen that fluidically couples inlet 123 and outlet 128 to one another.
- the lumen can be configured so as to extract heat from a fluid passing therethrough, e.g., in the direction denoted by arrow 112 illustrated in FIGS. 1A, IB, and 1G.
- hot-side heat exchanger 120 further can include fins disposed within the lumen of each of the one or more discrete channels 121.
- the fins can include any suitable composition.
- such fins can include, e.g., stainless steel, nickel plated copper, or stainless steel clad copper. Any suitable arrangement, number, and density of fins can be provided so as to facilitate extraction of heat from the fluid passing through the one or more discrete channels 121.
- a density of the fins within each of the one or more discrete channels is at least 12 fins per inch.
- the hot-side heat exchanger includes a high efficiency hot-side heat exchanger.
- high efficiency hot-side heat exchanger is intended to mean a hot-side heat exchanger
- a thermal resistance of less than about 0.0015m 2 K/W e.g., a thermal resistance of less than about 0.00025 m 2 K/W.
- hot-side heat exchanger 121 optionally can include at least one threaded rod 124 configured to sealingly couple the hot-side heat exchanger to a pipe flange or other suitable source of a fluid that carries waste heat.
- each of the one or more discrete channels 121 of heat exchanger 120 can include four threaded rods, two for coupling front plate 122 of hot- side heat exchanger 120 to a first region of a pipe flange, and two for coupling back plate 129 of hot-side heat exchanger to a second region of the pipe flange. It should be understood that any suitable type, number, and arrangement of fasteners can be used so as to couple hot side heat exchanger 121 to a source of a fluid that carries waste heat.
- first cold-side plate 110 and second cold-side plate 130 are substantially flat.
- substantially flat it is meant that the cold-side plate includes first and second major surfaces that each are substantially planar and parallel to one another, e.g., are characterized by a flatness and planarity specification of about 0.010" or less across the cold side plate.
- first cold-side plate 110 and second cold-side plate 130 each are substantially flat over substantially the entire lateral surface of thermoelectric generating unit 110.
- each of first cold-side plate 110 and second cold-side plate 130 can include a substantially flat slab of a thermally conductive material, such as a metal or a ceramic.
- Exemplary metals that can be suitable for use in one or both of first cold-side plate 110 and second cold-side plate 130 independently can be selected from the group consisting of aluminum, copper, molybdenum, tungsten, copper- molybdenum alloy, stainless steel, and nickel.
- Exemplary ceramics that can be suitable for use in one or both of first cold-side plate 110 and second cold-side plate 130 independently can be selected from the group consisting of silicon carbide, aluminum nitride, alumina, and silicon nitride.
- first cold-side plate 110 and second cold-side plate 130 can include a metal, e.g., an exemplary metal listed above, and the other of first cold-side plate 130 and second cold-side plate 130 can include a ceramic, e.g., an exemplary ceramic listed above.
- both first cold-side plate 110 and second cold-side plate 130 can include a metal, e.g., an exemplary metal listed above.
- both first cold-side plate 110 and second cold- side plate 130 can include a ceramic, e.g., an exemplary ceramic listed above.
- Each of the first cold-side plate 110 and second cold-side plate 130 can include a plurality of apertures defined therethrough for respectively receiving fasteners 111.
- the apertures can extend through the entire thickness of each of the substantially flat slabs.
- the apertures can extend through only a portion of the thickness of one or both of the substantially flat slabs.
- the apertures are arranged in a plurality of rows and a plurality of columns across the surface of each of the substantially flat slabs.
- first cold-side plate 110 and substantially second cold-side plate 130 include one or more channels defined therein that are configured to receive a fluidic coolant, e.g., a liquid or gaseous coolant.
- first cold-side plate 110 and second cold-side plate 130 can include one or more inlets 113a or 113b for coolant inflow and one or more outlets 113b or 113a for coolant outflow.
- the inlet 113a or 113b and outlet 113b or 113a for first cold-side plate 110 are on the same side of the first cold-side plate as one another
- the inlet 133a or 133b and outlet 133b or 133a for second cold-side plate 130 are on the same side of the second cold- side plate as one another, e.g., so as to facilitate ease of installation and access to the ports.
- first cold-side plate 110 and second cold-side plate 130 further can include pin fins, straight fins, or offset fins.
- the fins can be disposed inside of one or both of first cold-side plate 110 and second cold-side plate 130, e.g., can be disposed within channels respectively defined within one or both of first cold-side plate 110 and second cold-side plate 130.
- the fins can be used to provide extended surfaces or increased surface area to increase heat transfer.
- the fins can also change the hydraulic diameter and alter flow paths causing disruptions to the boundary layer, again increasing heat transfer.
- the pin fins optionally can be arranged in an in-line arrangement or in a staggered arrangement.
- thermoelectric generating unit further includes a first plurality of thermoelectric devices 161 arranged between first cold- side plate 110 and first side 126 of hot-side heat exchanger 120, and a second plurality of thermoelectric devices 171 arranged between second cold-side plate 130 and second side 127 of hot-side heat exchanger 120.
- first plurality of thermoelectric devices 161 can be provided as part of first thermoelectric assembly 160, and second plurality of thermoelectric devices 171 can be provided as part of second thermoelectric assembly 170.
- Exemplary embodiments of thermoelectric assemblies such as suitable for use in one or both of first thermoelectric assembly 160 and second thermoelectric assembly 170 are described below with reference to FIGS. 2A-2C.
- one or both of first plurality of thermoelectric devices 161 and second plurality of thermoelectric devices 171 can be disposed on a circuit board.
- First plurality of thermoelectric devices 161 can be arranged in columns and rows between first cold-side plate 110 and first side 126 of hot-side heat exchanger 120, and fasteners 111 respectively can be disposed within gaps between the columns and rows, e.g., so that the fasteners need not be passed through any of the thermoelectric devices 161 of the first plurality.
- second plurality of thermoelectric devices 171 can be arranged in columns and rows between second cold-side plate 130 and second side 127 of hot-side heat exchanger 120, and fasteners 111 respectively can be disposed within gaps between the columns and rows, e.g., so that the fasteners need not be passed through any of the thermoelectric devices 171 of the second plurality.
- thermoelectric devices 161, 171 of the first and second pluralities of thermoelectric devices can have any suitable configuration.
- each of the thermoelectric devices 161, 171 can include one or more thermoelectric legs, e.g., can include one or more p-type thermoelectric legs and one or more n-type thermoelectric legs.
- Each of the thermoelectric legs can include a thermoelectric material disposed between first and second conductive materials.
- the p-type thermoelectric legs can include a different material, or the same material but with different doping, than do the n-type thermoelectric legs.
- first plurality 161 and second plurality 171 of thermoelectric devices can include a thermoelectric material selected from the group consisting of: tetrahedrite, magnesium silicide, magnesium silicide stannide, silicon, silicon nanowire, bismuth telluride, skutterudite, lead telluride, TAGS (tellurium-antimony-germanium-silver), zinc antimonide, silicon germanium, a half-Heusler compound, or any other thermoelectric material known in the art or yet to be developed.
- a thermoelectric material selected from the group consisting of: tetrahedrite, magnesium silicide, magnesium silicide stannide, silicon, silicon nanowire, bismuth telluride, skutterudite, lead telluride, TAGS (tellurium-antimony-germanium-silver), zinc antimonide, silicon germanium, a half-Heusler compound, or any other thermoelectric material known in the art or yet to be developed.
- thermoelectric legs 161, 171 can include 1 to 100 p-type thermoelectric legs and 1 to 100 n-type thermoelectric legs, or 10 to 80 p-type thermoelectric legs and 10 to 80 n-type thermoelectric legs, or 20 to 60 p-type thermoelectric legs and 20 to 60 n-type thermoelectric legs, e.g., 48 p-type thermoelectric legs and 48 n-type thermoelectric legs.
- the number of p-type thermoelectric legs in a thermoelectric device can be, but need not necessarily be, the same as the number of n-type thermoelectric legs in that thermoelectric device.
- First plurality of thermoelectric devices 161 can be electrically connected so as to obtain current therefrom responsive to a temperature differential between hot-side heat exchanger 120 and first cold-side plate 110.
- Second plurality of thermoelectric devices 171 can be electrically connected so as to obtain current therefrom responsive to a temperature differential between hot-side heat exchanger 120 and second cold-side plate 130.
- first plurality of thermoelectric devices 161 is connected electrically in serial with second plurality of thermoelectric devices 171 using conductor(s)
- the exemplary external connections illustrated in FIG. IF include wiring
- thermoelectric assembly 160 141, 142, and 143.
- Positive wiring 141 and negative wiring 142 respectively extend from first thermoelectric assembly 160 and second thermoelectric assembly 170.
- Series wiring 143 extends from both first thermoelectric assembly 160 and second thermoelectric assembly 170 so as to connect assemblies 160, 170 electrically in series with one another.
- the thermoelectric devices respectively of first thermoelectric assembly 160 and second thermoelectric assembly 170 are wired in a series-parallel configuration internally.
- thermoelectric legs, electrical connections, and thermoelectric devices that suitably can be used in the present thermoelectric generating units
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- U.S. Patent Publication No. 2015/0147842 entitled “Arrays of filled nano structures with protruding segments and methods thereof
- U.S. Patent Publication No. 2015/0295074 entitled “Arrays of long nano structures in semiconductor materials and methods thereof
- U.S. Patent Application No. 14/679,837 filed April 6, 2015 and entitled “Flexible lead frame for multi-leg package assembly”
- nanostructures and methods of forming and transferring the same.
- thermoelectric generating unit 100 further can include a plurality of fasteners 111 extending between first cold-side plate 110 and second cold-side plate 130 at respective locations outside of the one or more discrete channels 121, e.g., between discrete channels 121, of hot-side heat exchanger 120. Additionally, or alternatively, fasteners 111 can be disposed within gaps between the thermoelectric devices plurality 171.
- Fasteners 111 can be configured so as to compress first plurality of thermoelectric devices 161 between first cold-side plate 110 and first side 126 of hot-side heat exchanger 120 and also can be configured so as to compress second plurality of thermoelectric devices 171 between second cold-side plate 130 and second side 127 of hot- side heat exchanger 120.
- any suitable number of fasteners 111 can be provided relative to the number of thermoelectric devices of first plurality of thermoelectric devices 161 or second plurality of thermoelectric devices 171.
- one, two, three, four, or more than one fastener 111 can be provided for each thermoelectric device of first plurality of thermoelectric devices 161 or second plurality of thermoelectric devices 171.
- one, two, three, four, or more than four thermoelectric devices of first plurality of thermoelectric devices 161 or second plurality of thermoelectric devices 171 can be provided for each fastener 111.
- thermoelectric devices 161, 171 optionally can be arranged in rows and columns.
- Fasteners 111 can be arranged in rows and columns that are laterally offset from the rows and columns of thermoelectric devices 161, 171 so as to pass between the rows and columns of thermoelectric devices 161, 171.
- fasteners 111 can include a bolt or screw.
- fasteners 111 can include bolt 114.
- fasteners 111 also can include a nut that can engage the threading of the bolt or screw so as to comply compression between first cold-side plate 110 and second cold-side plate 130.
- apertures through one or both of cold-side plate 110 and second cold-side plate 130 can include threading that can engage the threading of the bolt or screw so as to apply compression between first cold-side plate 110 and second cold-side plate 120.
- fasteners 111 also can include a spring, a Belleville washer, or a spring washer disposed along the bolt or screw.
- such a spring, Belleville washer, or spring washer can permit thermal expansion of components of thermal generating unit 100 with changes in operating temperature, e.g., so as to reduce the likelihood of damage to unit 100 based on such thermal expansion, while maintaining compression between first cold-side plate 110 and second cold-side plate 120.
- Fasteners 111 can include different numbers of such springs, Belleville washers, or spring washers disposed along the bolts or screws than one another.
- the fastener includes bolt 114 and four Belleville washers 115
- the fastener includes bolt 114 and two Belleville washers.
- One or more of the springs, Belleville washers, or spring washers can be arranged with opposite orientation to one or more other of the springs, Belleville washers, or spring washers so as to provide additional accommodation for thermal expansion.
- thermoelectric generating unit 100 optionally includes one or more layers configured to provide thermal insulation, electrical insulation, or both thermal and electrical insulation, between first plurality of thermoelectric devices 161 and one or both of hot-side heat exchanger 120 and first cold-side plate 110, or between second plurality of thermoelectric devices 171 and one or both of hot-side heat exchanger 120 and second cold- side plate 130.
- additional layers are represented in FIG.
- thermoelectric generating unit 100 can include at least one of the following: a kapton film disposed between first side 126 of hot-side heat exchanger 120 and at least one thermoelectric device 161 of the first plurality of thermoelectric devices; a kapton film disposed between second side 127 of hot-side heat exchanger 120 and at least one thermoelectric device 171 of the second plurality of thermoelectric devices; a kapton film disposed between first cold-side plate 110 and at least one thermoelectric device 161 of the first plurality of thermoelectric devices; a kapton film disposed between second cold-side plate 130 and at least one thermoelectric device 171 of the second plurality of thermoelectric devices; a mica sheet disposed between first side 126 of hot-side heat exchanger 120 and at least one thermoelectric device 161 of the first plurality of thermoelectric devices; a mica sheet disposed between second side 127 of hot-side heat exchanger 120 and at least one thermoelectric device 171 of the second plurality of thermoelectric devices;
- thermoelectric devices a graphite sheet disposed between second side 127 of hot-side heat exchanger 120 and at least one thermoelectric device 171 of the second plurality of thermoelectric devices; a gap pad disposed between first cold-side plate 110 and at least one thermoelectric device 161 of the first plurality of thermoelectric devices; a gap pad disposed between second cold-side plate 130 and at least one thermoelectric device 171 of the second plurality of thermoelectric devices; an anodized layer disposed between first cold-side plate 110 and at least one thermoelectric device 161 of the first plurality of thermoelectric devices; and an anodized layer disposed between second cold-side plate 130 and at least one thermoelectric device 171 of the second plurality of thermoelectric devices. Exemplary embodiments of various suitable layer are described below with reference to FIGS. 2A-2C.
- thermoelectric generating unit 100 illustrated in FIGS. 1A-1G further can include spacers 125 disposed between first cold-side plate 110 and second cold-side plate 130.
- spacers 125 can include a thermally insulative material that inhibits conduction of heat from hot-side heat exchanger 120 to one or both of first cold-side plate 110 and second cold-side plate 130 except via thermal pathways that pass through the thermoelectric devices 161, 171 respectively.
- FIGS. 1 A-1G illustrate an embodiment that includes a hot-side heat exchanger and cold-side plates disposed on either side of respective pluralities of thermoelectric devices
- other embodiments can include other numbers of hot- side heat exchangers, cold-side plates, and pluralities of thermoelectric devices.
- One exemplary embodiment can include a hot-side heat exchanger, a cold-side plate, a plurality of thermoelectric devices disposed between the hot-side heat exchanger and a cold-side plate, and a plurality of fasteners arranged so as to compress the plurality of thermoelectric devices.
- the hot-side heat exchanger, cold-side plate, thermoelectric devices, and fasteners can be arranged similarly as described elsewhere herein.
- thermoelectric generating unit is a scalable and modular power producing device.
- the TGU can be configured in different sizes and shapes so as suitably to fit a package space and/or to improve integration into a thermoelectric generator (TEG) system such as described in the above-mentioned U.S. Provisional Patent Application No. 62/059,092 and in PCT Patent Application No.
- TOG thermoelectric generator
- TGU suitably can be used independently of such a TEG, e.g., in a differently configured TEG, in another device, or as a standalone unit.
- the present TGU power output is greater than 300W at inlet temperatures between 450 °C to 600 °C and flows between 25 g/s to 50 g/s.
- the physical size of the TGU is 3 ft x 3 ft x 0.5 ft (10 ft 3 ) or less with a mass of ⁇ 75 kg.
- operating voltage of the TGU can be greater than 300 V with an open circuit voltage which can be greater than 600 V.
- the TGU includes a cold side heat exchanger (CHX) or cold plate (also referred to herein as a cold-side plate) that can include a high performance heat exchanger, which can include one or more pin fins, straight fins, offset fins, or other enhanced heat exchanger constructions.
- CHX or cold- side plate includes a plurality of pin fins
- the pin fins each can be about 0.5 mm in diameter with 0.5 mm spacing relative to one another in an inline configuration (staggered configurations or other arrangements, and other dimensions and spacings, are also possible).
- microchannel heat transfer effectively cools the cold side of the TGU.
- the terms "about” and “approximately” are intended to mean plus or minus ten percent of the stated value.
- the CHX or cold-side plate is constructed such that both the inlet and outlet of the coolant flow are on the same side of the plate as one another.
- this configuration provides U flow.
- U flow configuration can provide higher flow through the CHX or cold-side plate, which can increase both heat transfer and pressure drop.
- An illustrative configuration in which both the inlet and outlet of the coolant flow are on the same side of the plate as one another can facilitate easier access to the coolant fluid ports (inlet and outlet) for assembly and
- the electrical connections are also both on the same side of the TGU as one other and as the cooling fluid ports.
- such a configuration can facilitate all of the connections, both fluid and electrical, to be made on the same side of the TGU (or TEG, in certain embodiments), which can simplify assembly and maintenance procedures.
- dielectric insulation of the TGU can be provided in multiple ways.
- dielectric insulation can be provided at the powercard or TE (thermoelectric) device level with ceramic substrates partially, substantially, or completely isolating the electrical components from the CHX (cold-side plate) or the hot- side heat exchanger (HHX), or both.
- other dielectric protection can be used.
- the CHX or cold-side plate can be anodized, which can provide a relatively thin, electrically isolating layer.
- another exemplary configuration adds a thin layer of kapton or mica to the thermal interface materials (TIMs) to provide electrical isolation.
- a thin layer can be applied to either the hot or cold side TIMs or both sides.
- voltage leakage from the connections between the TE devices can be inhibited by taping the connections between TE devices with electrical tape or kapton so as to partially,
- a conformal coating can be added so as to partially, substantially, or completely electrically isolate the connections between TE devices.
- FIGS. 2A-2C schematically illustrate views of an exemplary thermoelectric assembly for use in a thermoelectric generating unit such as illustrated in FIGS. 1A-1G, according to some embodiments.
- Thermoelectric assembly 160 illustrated in FIGS. 2A-2C can correspond to one or both of thermoelectric assembly 160 and thermoelectric assembly 170 described above with reference to FIGS. 1A-1G.
- Thermoelectric assembly 160 illustrated in FIGS. 2A-2C can include first insulation layer 210, circuit board 220 including a plurality of thermoelectric devices 221 disposed thereon, thermal insulation layer 230, second insulation layer 240, third insulation layer 250, fourth insulation layer 260, fifth insulation layer 270, sixth insulation layer 280, and adhesive 290.
- First insulation layer 210 can be disposed over circuit board 220 and can be configured so as to provide thermal insulation, electrical insulation, or both thermal and electrical insulation between thermoelectric devices 221 disposed on circuit board 220 and a substantially flat cold-side plate, e.g., first cold-side plate 110 or second cold-side plate 130 described above with reference to FIGS. 1A-1G.
- first insulation layer 210 includes one or more films of kapton, two or more films of kapton, or three or more films of kapton, e.g., four films of kapton having a thickness of about 0.001 inches each.
- Circuit board 220 is disposed over thermal insulation layer 230 and includes a plurality of thermoelectric devices 221 disposed thereon.
- the thermoelectric devices 221 optionally can be grouped together in assemblies that include any suitable number of thermoelectric devices 221, e.g., one, more than one, more than two, or more than three thermoelectric devices 221, e.g., four thermoelectric devices.
- Thermoelectric devices 221, or the assemblies of thermoelectric devices 221, can be arranged in columns and rows in a manner such as illustrated in FIGS. 4A-4B.
- Thermal insulation layer 230 can be disposed over second insulation layer 240 and can include any suitable thermal insulation material that can inhibit heat from being dissipated from the hot side to the cold side without going through thermoelectric devices 221, and also can inhibit thermal shorting in regions where thermoelectric devices 221 are not present.
- Second insulation layer 240, third insulation layer 250, fourth insulation layer 260, fifth insulation layer 270, and sixth insulation layer 280 can be selected so as to provide any suitable degree of thermal insulation, electrical insulation, or both thermal and electrical insulation between circuit board 220 and thermoelectric devices 221 disposed therein, and a hot-side heat exchanger, e.g., hot-side heat exchanger 120 described above with reference to FIGS. 1A-1G.
- second insulation layer 240 is disposed over third insulation layer 250 and includes one or more films of kapton, two or more films of kapton, or three or more films of kapton, e.g., one film of kapton having a thickness of about 0.001 inch.
- third insulation layer 250 is disposed over fourth insulation layer 260 and fifth insulation layer 270 and can include one or more graphite sheets, two or more graphite sheets, or three or more graphite sheets, e.g., one graphite sheet having a thickness of about 0.25 inches.
- the dotted lines at 251 are intended to indicate the exemplary relative alignment between third insulation layer 250, fourth insulation layer 260, and fifth insulation layer 270.
- fourth insulation layer 260 is disposed adjacent to fifth insulation layer 270 and under only a subset of thermoelectric devices 121 (with one or more layers disposed in between), and can include one or more graphite sheets, two or more graphite sheets, or three or more graphite sheets, e.g., one graphite sheet having a thickness of about 0.25 inches.
- fifth insulation layer 270 is disposed adjacent to sixth insulation layer 280, adjacent to fourth insulation layer 260, and under only a subset of thermoelectric devices 121 (with one or more layers disposed in between), and can include one or more mica sheets, two or more mica sheets, or three or more mica sheets, e.g., ten mica sheets having a thickness of about 0.008 inches each.
- sixth insulation layer 280 is disposed adjacent to fifth insulation layer 270, and under only a subset of thermoelectric devices 121 (with one or more layers disposed in between), and can include one or more mica sheets, two or more mica sheets, or three or more mica sheets, e.g., seven mica sheets having a thickness of about 0.020 inches each.
- the mica sheets of fifth insulation layer 270 and sixth insulation layer 280 optionally can include a combination of mica and graphite.
- Adhesive 290 e.g., kapton tape, can be used to adhere the different insulation layers to one another and to second insulation layer 240 in a manner such as illustrated in FIGS. 2B-2C.
- sixth insulation layer 280 can be disposed adjacent to the inlets of the one or more discrete channels of the hot-side heat exchanger, e.g., where the fluid carrying the waste heat can be the hottest.
- Fifth insulation layer 270 can be disposed adjacent to a central portion of the one or more discrete channels of the hot-side heat exchanger, e.g., where the fluid carrying the waste heat is cooler than at the inlet.
- Fourth insulation layer 260 can be disposed adjacent to the outlets of the one or more discrete channels of the hot-side heat exchanger, e.g., where the fluid carrying the waste heat can be still cooler than in the central portion.
- Sixth insulation layer 280 can provide greater thermal insulation between thermoelectric devices 221 and the hot-side heat exchanger than does fifth insulation layer 270
- an fifth insulation layer 270 can provide greater thermal insulation between thermoelectric devices 221 and the hot-side heat exchanger than does fourth insulation 260.
- a suitable amount of heat can be transmitted through the respective insulation layer 260, 270, or 280 to the thermoelectric devices 221 disposed over that layer, while sufficiently protecting the thermoelectric devices 221 from being damaged by that heat.
- FIGS. 2A-2C are intended to be purely illustrative, and not limiting.
- One or more of the insulation layers suitably can be omitted or modified so as to facilitate transfer of heat from the fluid to the thermoelectric devices, while suitably protecting the thermoelectric devices from damage by that heat.
- the TE devices are connected together on a circuit board or printed wiring harness, so as to reduce the complexity and amount of wiring.
- the traces of the circuit board can be properly electrically isolated from one another.
- the TGU can include a configuration of clamping bolts that go through the circuit board or wiring harness.
- the bolts can be electrically isolated, e.g., by applying kapton tape to them and/or a high temperature electrically isolating coating.
- An exemplary TGU prepared as provided herein was tested on a hi pot tester, passing at voltages greater than 2 kV.
- the exemplary TGU was also tested with a mega-ohm meter where fully parallel (all heat exchangers connected together) resistances were measured exceeding 50 Mohm.
- the TGU includes two CHX or cold- side plates and one set of hot heat exchanger (HHX) channels sandwiching two sets of TE devices or powercards connected electrically together on a circuit board or printed wiring harness.
- the fluid flows of the CHX (cold-side plate) and HHX can be configured in a cross flow construction relative to one another, although counter and parallel flow configurations are also options.
- An alternative construction allows for alternating CHX (cold-side plate) and HHX with the TE circuit board sandwiched in between, and in some embodiments there can be one more CHX (cold-side plate) than HHX set.
- the HHX set includes a plurality of separate HHX channels, e.g., two, three, four, five, six, seven, eight, nine, ten, or more than ten HHX channels, connected fluidically in parallel with one another so as to enhance thermal expansion protection.
- a configuration can reduce thermal stress in the TGU.
- hot heat exchangers can experience exemplary temperatures from -40 °C or less to 600 °C or greater.
- the length of the hot heat exchangers can be reduced and therefore the absolute expansion can be reduced.
- expansion occurs in between hot heat exchanger channels, which can reduce effects on interface with the rest of the TGU.
- such a configuration can increase repeatability of part, thus, in some embodiments, reducing cost through volume.
- such a configuration also can improve quality of hot heat exchanger build, e.g., by reducing maximum length of the fin pack, braze surface, and the like.
- modular configuration of some embodiments can allow for integration into TGUs of various sizes by adding or removing channels.
- one or more fasteners can be configured so as to apply different forces than one or more other fasteners across the TGU.
- a first subset of the first plurality of thermoelectric devices 161 is centrally disposed and a second subset of the first plurality of thermoelectric devices 171 is peripherally disposed.
- a first subset of the plurality of fasteners 111 apply a first force to the first subset of the first plurality of thermoelectric devices and a second subset of the plurality of fasteners 111 apply a second force to the second subset of the first plurality of thermoelectric devices, where the first force is greater than the second force.
- the first force is at least 1.5 times the second force.
- a third subset of the first plurality of thermoelectric devices 161 can be disposed between the first subset of the first plurality of thermoelectric devices 161 and the third subset of the first plurality of thermoelectric devices 161.
- a third subset of the plurality of fasteners 111 apply a third force to the third subset of the first plurality of thermoelectric devices 161, where the third force is less than the first force and greater than the second force.
- the first force is about 1.5 times the third force
- the first force is about 3 times the second force.
- the first force can be about 11-13 kN
- the third force can be about 7-9 kN
- the second force can be about 3-5 kN.
- such a distribution of forces can provide a substantially uniform pressure of the TGU, e.g., a substantially uniform pressure of 80 psi across the TGU.
- the bolt pattern for the TGU layout utilizes unequal bolt torqueing.
- controlling interface pressure at hot and cold junctions of the TGU can be useful so as to enhance performance.
- pressure can be controlled locally.
- bolt loading is selected so as to account for, or to offset, stiffness effects of other TGU components.
- fasteners 111 can include a bolt or screw, and also can include a spring, a Belleville washer, or a spring washer disposed along the bolt or screw.
- such a spring, Belleville washer, or spring washer can permit thermal expansion of components of thermal generating unit 100 with changes in operating temperature, e.g., so as to reduce the likelihood of damage to unit 100 based on such thermal expansion, while maintaining compression between first cold-side plate 110 and second cold- side plate 120.
- the first subset of the plurality of fasteners optionally can include a greater number of springs, Belleville washers, or spring washers disposed along the bolts or screws of that subset than does the second subset of the plurality of fasteners.
- FIGS. 3A-3C schematically illustrate exemplary arrangements of fasteners for use in a thermoelectric generating unit such as illustrated in FIGS. 1A-1G, according to some embodiments.
- FIG. 3 A illustrates a top view of first cold-side plate 110 similar to that described above with reference to FIGS. 1A-1G, with annotations representing an exemplary fastener configuration at different locations through first cold-side plate 110. More specifically, in FIG. 3A, the annotation "A" indicates that the fastener configuration illustrated in FIG. 3B is used, and the annotation "B" indicates that the fastener configuration illustrated in FIG. 3C is used.
- the annotations 1-30 indicate the number designation of the respective fasteners. Table 1 below summarizes one exemplary set of torques that can be applied to the various fasteners (e.g., bolts) represented in FIG. 3A on different passes:
- FIG. 4A schematically illustrates one nonlimiting example of an arrangement of fasteners for use in a thermoelectric generating unit such as illustrated in FIGS. 1A-1G, according to some embodiments.
- FIG. 4A illustrates a schematic showing one exemplary embodiment in which unequal fastener (bolt) torque values can be used to create a partially, substantially, or completely uniform pressure on or across some or all of the TE devices of the TGU.
- bolt fastener
- FIG. 4B schematically illustrates one nonlimiting example of a distribution of pressures that can be obtained using the arrangement of fasteners illustrated in FIG. 4A.
- FIG. 4B illustrates exemplary simulation results showing substantial pressure uniformity on each of the TE devices in the circuit board in the TGU based on the nonlimiting, exemplary bolt torque values illustrated in FIG. 4A.
- each assembly 461 includes four TE devices 462. Additionally, in FIGS. 4A and 4B, it can be seen that the assemblies are arranged in columns 401-405 and rows 411-414 and that the fasteners are disposed between the columns and rows.
- the thermal interface along the length of the HHX in the flow direction can be varied.
- Such a configuration can facilitate the use of the TGU in higher temperature exhaust applications by reducing the TE junction temperature at the hottest location below its upper limit.
- Such a configuration also can improve consistency of the hot junction temperature of the TE devices, e.g., can partially, substantially, or completely equalize the hot junction temperature of the TE devices, such that the TE devices can operate at a suitable load, illustratively, at an optimal load.
- compact thermal expansion management is utilized.
- the TGU can undergo thermal expansion during operation (such expansion can be steady state or cyclic, or both steady state and cyclic).
- the incorporation of Belleville washers can facilitate bolt (fastener) loads— and therefore pressure on the TE devices— to remain relatively stable over a portion of or over the entire operating range of the TGU.
- a gap pad can be used as an interface between CHX and a cold junction of thermal interface material, and in some embodiments, such gap pad can be made thicker than thermally necessary so as to partially, substantially, or completely absorb some of such expansion.
- strategic heat transfer fin location can be utilized within either the HHX and/or the CHX so as to enhance localized heat transfer and to reduce heat exchanger pressure drop.
- TE devices need not necessarily be located across the entire area of an HHX and/or CHX.
- fins are located where needed, and need not necessarily be located where fins are not needed.
- fin density can be varied in different areas of the TGU so as to enhance thermal impedance match in different areas of the TGU.
- tortuous path sealing can be utilized so as to inhibit exhaust gas leakage within the TGU.
- scallop and gusset features can be utilized so as to inhibit exhaust gas leakage.
- FIG. 5 illustrates a plot of exemplary power output as a function of exhaust flow for a thermoelectric generating unit such as illustrated in FIGS. 1A-1G, according to some embodiments.
- FIG. 5 it can be understood that based upon an increase in the exhaust flow through the hot-side heat exchanger of the present thermoelectric generating unit
- thermoelectric generating unit increases. Additionally, in FIG. 5, it can be understood that based upon an increase in the inlet temperature of the exhaust flow through the hot-side heat exchanger of the present thermoelectric generating unit ("PowerModule"), the gross power produced by the thermoelectric generating unit increases.
- FIG. 6 illustrates a plot of exemplary pressure drop as a function of exhaust flow for a thermoelectric generating unit such as illustrated in FIGS. 1A-1G, according to some embodiments.
- FIG. 6 it can be understood that based upon an increase in the exhaust flow through the hot-side heat exchanger of the present thermoelectric generating unit
- FIG. 7 schematically illustrates steps in an exemplary method of preparing a thermoelectric generating unit, according to some embodiments.
- Method 700 includes providing a hot-side heat exchanger including a first side, a second side, and one or more discrete channels (701). Exemplary embodiments of hot-side heat exchangers are provided elsewhere herein, e.g., with reference to FIGS. 1A-1G.
- Method 700 illustrated in FIG. 7 also includes providing a substantially flat first cold-side plate (702) and providing a substantially flat second cold-side plate (703).
- Exemplary embodiments of cold-side plates are provided elsewhere herein, e.g., with reference to FIGS. 1A-1G.
- Method 700 illustrated in FIG. 7 also includes arranging a first plurality of thermoelectric devices between the first cold-side plate and the first side of the hot-side heat exchanger (704) and arranging a second plurality of thermoelectric arranged between the second cold-side plate and the second side of hot-side heat exchanger (705).
- Exemplary arrangements of thermoelectric devices between a cold-side plate and a heat exchanger are provided elsewhere herein, e.g., with reference to FIGS. 1A-1G, 2A-2C, 3A, and 4A-4B.
- Method 700 illustrated in FIG. 7 also includes disposing a plurality of fasteners extending between the first cold-side plate and the second cold-side plate at respective locations outside of the one or more discrete channels of the hot-side heat exchanger and within gaps between the thermoelectric devices of the first plurality and within gaps between the thermoelectric devices of the second plurality (706).
- exemplary arrangements and configurations of fasteners are provided elsewhere herein, e.g., with reference to FIGS. 1 A- 1G, 3A-3C, and 4A-4B.
- Method 700 illustrated in FIG. 7 further includes compressing by the fasteners the first plurality of thermoelectric devices between the first cold-side plate and the first side of the hot-side heat exchanger and the second plurality of thermoelectric devices between the second cold-side plate and the second side of the hot-side heat exchanger (707).
- Exemplary torques with which the fasteners can be tightened and exemplary forces and pressures that can be exerted by such fasteners are provided elsewhere herein, e.g., with reference to FIGS. 1A-1G, 3A-3C, and 4A-4B.
- method 700 includes centrally disposing a first subset of the first plurality of thermoelectric devices; peripherally disposing a second subset of the first plurality of thermoelectric devices; applying a first force to the first subset of the first plurality of thermoelectric devices with a first subset of the plurality of fasteners; and applying a second force to the second subset of the first plurality of thermoelectric devices with a second subset of the plurality of fasteners, wherein the first force is greater than the second force, e.g., in a manner such as described above with reference to FIGS. 3A-3C and 4A-4B.
- the first force is at least 1.5 times the second force.
- each fastener can include a bolt or screw; and a spring, a Belleville washer, or a spring washer disposed along the bolt or screw.
- the first subset of the plurality of fasteners includes a greater number of springs, Belleville washers, or spring washers disposed along the bolts or screws of that subset than does the second subset of the plurality of fasteners.
- Method 700 optionally also can include disposing a third subset of the first plurality of thermoelectric devices is between the first subset of the first plurality of thermoelectric devices and the third subset of the first plurality of thermoelectric devices; and applying a third force to the third subset of the first plurality of thermoelectric devices with a third subset of the plurality of fasteners, wherein the third force is less than the first force and greater than the second force, e.g., in a manner such as described above with reference to FIGS. 3A-3C and 4A-4B.
- the first force can be about 1.5 times the third force, and the first force can be about 3 times the second force.
- the first force can be about 11-13 kN
- the third force can be about 7-9 kN
- the second force can be about 3-5 kN.
- such a distribution of forces can provide a substantially uniform pressure of the TGU, e.g., a substantially uniform pressure of 80 psi across the TGU.
- method 700 further include arranging the first plurality of thermoelectric devices in columns and rows between the first cold-side plate and the first side of the hot-side heat exchanger; and respectively disposing the fasteners within gaps between the columns and rows.
- method 700 can include disposing four fasteners for every four thermoelectric devices of the first plurality of thermoelectric devices and for every four thermoelectric devices of the second plurality of thermoelectric devices. But it should be understood that other numbers of fasteners suitably can be used.
- the hot-side heat exchanger further includes fins disposed within each of the one or more discrete channels.
- the fins can include stainless steel, nickel plated copper, or stainless steel clad copper.
- a density of the fins within each of the one or more discrete channels is at least 12 fins per inch.
- the hot-side heat exchanger includes at least one threaded rod
- method 700 further can include sealingly coupling the hot-side heat exchanger to a pipe flange via the at least one threaded rod.
- the first cold-side plate further includes pin fins, straight fins, or offset fins.
- the pin fins can be arranged in an in-line arrangement or in a staggered arrangement, or include brazed offset pin fins.
- Some embodiments of method 700 further include disposing the first plurality of thermoelectric devices on a circuit board.
- the first plurality of thermoelectric devices include a thermoelectric material, the thermoelectric material being selected from the group consisting of: tetrahedrite, magnesium silicide, magnesium silicide stannide, silicon, silicon nanowire, bismuth telluride, skutterudite, lead telluride, TAGS (tellurium-antimony- germanium- silver), zinc antimonide, silicon germanium, and a half-Heusler compound.
- At least one of the first cold-side plate and the second cold-side plate includes a high efficiency cold-side heat exchanger; and the hot- side heat exchanger includes a high efficiency hot-side heat exchanger.
- the first cold-side plate includes an inlet for coolant inflow and an outlet for coolant outflow, wherein the inlet and outlet are on the same side of the first cold-side plate as one another.
- Some embodiments of method 700 further include at least one of the following: disposing a kapton film between the first side of the hot-side heat exchanger and at least one thermoelectric device of the first plurality of thermoelectric devices; disposing a kapton film between the first cold-side plate and at least one thermoelectric device of the first plurality of thermoelectric devices; disposing a mica sheet between the first side of the hot-side heat exchanger and at least one thermoelectric device of the first plurality of thermoelectric devices; disposing a graphite sheet between the first side of the hot-side heat exchanger and at least one thermoelectric device of the first plurality of thermoelectric devices; disposing a gap pad between the cold-side plate and at least one thermoelectric device of the first plurality of thermoelectric devices; and disposing an anodized layer between the cold-side plate and at least one thermoelectric device of the first plurality of thermoelectric devices.
- the company's first product attaches to an exhaust stack, and captures waste heat and uses Alphabet's patented thermoelectric materials to convert it to electricity.
- Thermoelectrics use a heat differential to create electricity; one side is hot, and the other is cold, and the temperature differential between the two forces electrons to create a current.
- thermoelectrics While NASA has used thermoelectrics since the 1950s, materials costs made them cost-prohibitive. However, new advancements in silicon and tetrahedrite have led Alphabet to create highly efficient thermoelectric materials using abundant resources. Thermoelectrics are unique because they are solid-state; which means the El has no moving parts, no working fluids and requires no maintenance.
- the El generates up to 25kW per l,000kWe diesel generator, which means 1% energy efficiency.
- the electricity the El creates can power additional hardware and/or augment power to existing systems, reducing electrical load and in turn, reducing fuel consumption and operating costs.
- turnkey systems ship in a single, standard shipping container and save more than 60,000 liters of diesel fuel per year when operating on a l,000kW diesel engine.
- the El requires no engine modifications and is installed during a simple process that involves exhaust coupling and electrical hookup. Standard connection is complete in less than two hours. All updates to the host engine's (or turbine's) exhaust system are performed within a standard engine maintenance service interval and the El complies with all major engine manufacturer back pressure limits and warranty specs.
- thermoelectric materials are a platform technology with a wide array of potential applications including power generation associated: remote sensors, surveillance, telemetry, automobiles, trucks, locomotives, mining equipment, ships, jet engines, factory exhaust flues, and many more.
- Alphabet Energy has over 50 patents registered or pending.
- the top caliber team includes many of the top minds in thermoelectrics and materials science and a wealth of experience from the oil & gas, automotive, and power generation industries.
- Alphabet Energy has raised over $30 million in funding from top investors including TPG and Encana.
- thermoelectric generator When we set out to build the world's first industrial-scale thermoelectric generator, we knew it had to behave as a piece of simple industrial equipment rather than a complex power plant. We put together a team that combined decades of experience in the oil & gas, mining, engine, and burner industries with the brightest minds in solid-state power generation.
- the El 's benefits are delivered instantly: several percent savings in fuel and a very short payback time on a small amount of up-front capital.
- the El is optimized for continuous engines 800 to 1400 kW in size running diesel or natural gas, but works on any engine or exhaust source.
- the DC electricity is delivered to the pre-packaged power electronics which inverts the power to AC at the same phase and voltage that the engine delivers.
- the cooled exhaust then flows up and out of the container at about 200 degrees Celsius. All the while, the El 's pre-packaged radiators keep the modules cool.
- thermoelectric generating unit in another example, includes a hot-side heat exchanger including a first side, a second side, and one or more discrete channels; a first cold-side plate; and a second cold-side plate.
- the thermoelectric generating unit further can include a first plurality of thermoelectric devices arranged between the first cold-side plate and the first side of the hot-side heat exchanger; and a second plurality of thermoelectric devices arranged between the first cold-side plate and the first side of the hot-side heat exchanger.
- the thermoelectric generating unit further can include a plurality of fasteners disposed within gaps between the thermoelectric devices of the first plurality, the fasteners compressing the first plurality of thermoelectric devices between the first cold-side plate and the first side of the hot-side heat exchanger.
- the plurality of fasteners further can be disposed within gaps between the thermoelectric devices of the second plurality, the fasteners compressing the second plurality of thermoelectric devices between the second cold-side plate and the second side of the hot-side heat exchanger.
- the fasteners can extend from the first cold-side plate to the second cold-side plate at respective locations outside of the one or more discrete channels of the hot-side heat exchanger. Non-limiting examples of such an embodiment are provided herein, e.g., with reference to FIGS. 1A-1G, 3A-3C, 4A, and 4B.
- a method of assembling a thermoelectric generating unit includes providing a hot-side heat exchanger including a first side, a second side, and one or more discrete channels.
- the method also can include providing a substantially flat first cold- side plate; and providing a substantially flat second cold-side plate.
- the method also can include arranging a first plurality of thermoelectric devices between the first cold-side plate and the first side of the hot-side heat exchanger; and arranging a second plurality of thermoelectric arranged between the second cold-side plate and the second side of hot-side heat exchanger.
- the method also can include disposing a plurality of fasteners extending between the first cold-side plate and the second cold-side plate at respective locations outside of the one or more discrete channels of the hot-side heat exchanger and within gaps between the thermoelectric devices of the first plurality and within gaps between the thermoelectric devices of the second plurality.
- the method also can include compressing by the fasteners the first plurality of thermoelectric devices between the first cold-side plate and the first side of the hot-side heat exchanger and the second plurality of thermoelectric devices between the second cold-side plate and the second side of the hot-side heat exchanger.
- Non-limiting examples of such an embodiment are provided herein, e.g., with reference to FIGS. 1A-1G, 3A-3C, 4A, 4B, and 7.
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- Chemical & Material Sciences (AREA)
- Inorganic Chemistry (AREA)
- Engineering & Computer Science (AREA)
- General Physics & Mathematics (AREA)
- Physics & Mathematics (AREA)
- Condensed Matter Physics & Semiconductors (AREA)
- Manufacturing & Machinery (AREA)
- Computer Hardware Design (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Power Engineering (AREA)
- Cooling Or The Like Of Semiconductors Or Solid State Devices (AREA)
- Heat-Exchange Devices With Radiators And Conduit Assemblies (AREA)
- Cooling Or The Like Of Electrical Apparatus (AREA)
Abstract
Description
Claims
Priority Applications (6)
Application Number | Priority Date | Filing Date | Title |
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CA2963265A CA2963265A1 (en) | 2014-10-02 | 2015-10-01 | Thermoelectric generating unit and methods of making and using same |
JP2017517305A JP2017539074A (en) | 2014-10-02 | 2015-10-01 | Thermoelectric power generation unit and method for producing and using the same |
EP15846902.3A EP3201956A1 (en) | 2014-10-02 | 2015-10-01 | Thermoelectric generating unit and methods of making and using same |
CN201580062387.6A CN107004754A (en) | 2014-10-02 | 2015-10-01 | Thermoelectric power generation unit and its making and use method |
KR1020177011212A KR20170063817A (en) | 2014-10-02 | 2015-10-01 | Thermoelectric generating unit and methods of making and using same |
AU2015324942A AU2015324942A1 (en) | 2014-10-02 | 2015-10-01 | Thermoelectric generating unit and methods of making and using same |
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US201462059084P | 2014-10-02 | 2014-10-02 | |
US62/059,084 | 2014-10-02 |
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WO2016054333A1 true WO2016054333A1 (en) | 2016-04-07 |
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PCT/US2015/053434 WO2016054333A1 (en) | 2014-10-02 | 2015-10-01 | Thermoelectric generating unit and methods of making and using same |
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EP (1) | EP3201956A1 (en) |
JP (1) | JP2017539074A (en) |
KR (1) | KR20170063817A (en) |
CN (1) | CN107004754A (en) |
AU (1) | AU2015324942A1 (en) |
CA (1) | CA2963265A1 (en) |
WO (1) | WO2016054333A1 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
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US11997838B2 (en) | 2022-02-01 | 2024-05-28 | Toyota Motor Engineering & Manufacturing North America, Inc. | Power device assemblies and methods of fabricating the same |
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KR102142384B1 (en) * | 2019-01-29 | 2020-08-07 | 주식회사 경원이앤씨 | An Thermoelectric Generation Apparatus and Control method thereof |
KR102083611B1 (en) | 2019-04-25 | 2020-03-02 | 엘지이노텍 주식회사 | Heat conversion device |
KR102249020B1 (en) | 2020-02-25 | 2021-05-07 | 엘지이노텍 주식회사 | Heat conversion device |
CN116458281A (en) * | 2020-11-04 | 2023-07-18 | Lg伊诺特有限公司 | Heat conversion device and power generation system comprising same |
WO2024011312A1 (en) * | 2022-07-13 | 2024-01-18 | National Thermovoltaics Inc. | Thermoelectric generator apparatuses and systems |
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US20070157629A1 (en) * | 2004-03-02 | 2007-07-12 | Peltech S.R.L. | Thermoelectric heat pumps |
US20130034080A1 (en) * | 2011-08-02 | 2013-02-07 | Qualcomm Incorporated | Method for fast return to source rat (radio access technology) after redirection to target rat |
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US3197343A (en) * | 1962-07-05 | 1965-07-27 | Carrier Corp | Thermoelectric panels |
US20060157102A1 (en) * | 2005-01-12 | 2006-07-20 | Showa Denko K.K. | Waste heat recovery system and thermoelectric conversion system |
DE102010022225A1 (en) * | 2010-04-28 | 2011-12-15 | J. Eberspächer GmbH & Co. KG | Heat transfer assembly, heat exchanger and manufacturing process |
DE102010054432B4 (en) * | 2010-12-14 | 2023-02-09 | Friedrich Boysen Gmbh & Co. Kg | Device for converting thermal energy into electrical energy, as well as system and exhaust system with such a device |
FR2972570B1 (en) * | 2011-03-10 | 2016-06-10 | Valeo Systemes Thermiques | MODULE AND ELECTRIC THERMO DEVICE, PARTICULARLY FOR GENERATING AN ELECTRICAL CURRENT IN A MOTOR VEHICLE |
US20130000285A1 (en) * | 2011-06-28 | 2013-01-03 | GM Global Technology Operations LLC | Internal combustion engine exhaust thermoelectric generator and methods of making and using the same |
CN104412402A (en) * | 2012-06-25 | 2015-03-11 | Gmz能源公司 | Thermoelectric power generation system using gradient heat exchanger |
AU2013286602A1 (en) * | 2012-07-06 | 2015-01-29 | Board Of Trustees Of Michigan State University | Thermoelectric materials based on tetrahedrite structure for thermoelectric devices |
-
2015
- 2015-10-01 CA CA2963265A patent/CA2963265A1/en not_active Abandoned
- 2015-10-01 AU AU2015324942A patent/AU2015324942A1/en not_active Abandoned
- 2015-10-01 KR KR1020177011212A patent/KR20170063817A/en unknown
- 2015-10-01 JP JP2017517305A patent/JP2017539074A/en active Pending
- 2015-10-01 EP EP15846902.3A patent/EP3201956A1/en not_active Withdrawn
- 2015-10-01 CN CN201580062387.6A patent/CN107004754A/en active Pending
- 2015-10-01 WO PCT/US2015/053434 patent/WO2016054333A1/en active Application Filing
Patent Citations (3)
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US4782664A (en) * | 1987-09-16 | 1988-11-08 | Allied Products Corporation | Thermoelectric heat exchanger |
US20070157629A1 (en) * | 2004-03-02 | 2007-07-12 | Peltech S.R.L. | Thermoelectric heat pumps |
US20130034080A1 (en) * | 2011-08-02 | 2013-02-07 | Qualcomm Incorporated | Method for fast return to source rat (radio access technology) after redirection to target rat |
Cited By (1)
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US11997838B2 (en) | 2022-02-01 | 2024-05-28 | Toyota Motor Engineering & Manufacturing North America, Inc. | Power device assemblies and methods of fabricating the same |
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AU2015324942A1 (en) | 2017-04-20 |
EP3201956A1 (en) | 2017-08-09 |
CA2963265A1 (en) | 2016-04-07 |
KR20170063817A (en) | 2017-06-08 |
CN107004754A (en) | 2017-08-01 |
JP2017539074A (en) | 2017-12-28 |
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