Modular Thermoelectric Generator with Direct Fluid Coupling
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Solution Overview
Problem
Existing thermoelectric generators face construction complexity, high production costs, and maintenance difficulties due to specialized components and indirect heat exchange methods, limiting their efficiency and versatility beyond motor vehicle applications.
Innovation Solution
A thermoelectric generator design utilizing market-available Seebeck effect cells supported by flat laminar elements and insulating panels, allowing direct heat exchange and simplified assembly through mechanical fixing, excluding costly machining operations, and enabling modular expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If thermoelectric converters are shaped specifically for the application and arranged in coaxial configuration, then the generator can efficiently convert heat energy to electric energy, but the construction becomes complex and maintenance operations become difficult
Solution Approach 1:
The generator is divided into multiple modular units, each containing a thermoelectric converter assembly. These modules can be independently manufactured, assembled, and replaced. The segmentation allows standard thermoelectric converters to be used without requiring complex custom shaping, while maintaining efficient heat-to-electric energy conversion through the modular architecture.
Solution Approach 2:
The generator design uses universal, standard thermoelectric converters that can be applied in multiple configurations and applications. The same type of converter is used throughout the system, eliminating the need for specialized custom-shaped converters. This universality simplifies construction while maintaining power conversion efficiency through proper thermal coupling design.
2Ease of manufacture
If heat exchange occurs through interposition of exchangers and dissipators, then the generator can be constructed with standardized components, but the efficiency of heat exchange between thermoelectric converters and fluids decreases
Solution Approach 1:
The intermediate heat exchanger and dissipator components are removed from the system. Instead, the thermoelectric converters are directly coupled to the fluid flow paths, allowing hot and cold fluids to exchange heat directly with the converter surfaces. This extraction of intermediary components eliminates the thermal resistance they introduce while maintaining construction simplicity through direct coupling mechanisms.
Solution Approach 2:
The patent introduces optimized thermal coupling elements that serve as efficient mediators between the thermoelectric converters and the fluids. These coupling elements provide direct thermal pathways with minimal resistance, replacing the traditional multi-layer exchanger/dissipator structure. The mediators maintain ease of manufacture while dramatically improving heat exchange efficiency through enhanced thermal conductivity and reduced interface resistance.
3Volume of moving object
If specialized shaped converters and stacked disk configurations are used, then the generator can achieve compact design, but production costs increase and repair operations become difficult
Solution Approach 1:
The compact generator design is achieved through segmentation into modular units that can be easily disassembled and reassembled. Each module contains standard thermoelectric converters in a compact arrangement, but the modular nature allows individual modules to be removed and replaced without disassembling the entire stack. This segmentation maintains compactness while dramatically improving maintenance accessibility.
Solution Approach 2:
The design uses standard, commercially available thermoelectric converters instead of expensive custom-shaped ones. These standard converters can be easily replaced if needed, and the modular architecture allows for economical replacement of individual modules rather than the entire system. This approach reduces production costs and simplifies repair operations while maintaining a compact overall design.
4Power
If the generator design is optimized for motor vehicle applications, then it can efficiently utilize exhaust heat, but the versatility for use in other sectors and systems is limited
Solution Approach 1:
The generator is designed with universal thermoelectric converters and a flexible modular architecture that can be adapted to various heat sources and applications. The same basic design can be applied to vehicle exhaust heat, industrial waste heat, geothermal sources, or any other temperature differential source. This universality maintains efficient heat-to-electric energy conversion while dramatically expanding adaptability to different sectors and systems.
Solution Approach 2:
The generator design incorporates dynamic adaptability through its modular configuration, allowing the system to be adjusted and reconfigured for different applications. The modular units can be added or removed based on the specific heat source characteristics and power requirements of different applications, from mobile vehicle systems to stationary industrial installations, maintaining optimal performance across diverse uses.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design simplifies construction, reduces costs, enhances efficiency by direct heat exchange, and increases power density, making the generator more versatile for use in static systems with improved maintenance accessibility and potential for power augmentation.
Implementation Method 1
Seebeck effect cells are thermoelectric converters capable of producing electric energy when one of their surfaces is heated and the opposite surface is cooled
Data Source
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AI summary
The invention is a thermoelectric generator (1; 100) comprising: a containment body (2; 102) provided with walls (12a; 111) delimiting a heat exchange chamber (12; 112), in which it is possible to identify a first inlet way (3; 103) and a first outlet way (4; 104) of a first heat exchange fluid (C) and a second inlet way (5; 105) and a second outlet way (6; 106) of a second heat exchange fluid (F); a plurality of thermoelectric converters (20; 120) arranged inside the containment body (2; 102), each one of which has a first surface (20a; 120a) facing towards the first heat exchange fluid (C) and a second surface (20b; 120b), opposite the first surface (20a; 120a), facing towards the second heat exchange fluid (F). The thermoelectric converters (20; 120) are constituted by cells with Seebeck effect that are supported by spaced laminar elements (7; 107) that face corresponding thermally insulating panels (8; 108) so as to define, inside the containment body (2; 102), a plurality of first flow ducts (9; 109) communicating with the first inlet ways (3; 103) and outlet ways (4; 104) for the circulation of the first heat exchange fluid (C), and a plurality of second flow ducts (10; 110) communicating with the second inlet ways (5; 105) and outlet ways (6; 106) for the circulation of the second heat exchange fluid (F). Each one of the first flow ducts (9; 109) is arranged adjacent and parallel to a corresponding second flow duct (10; 110) and each one of the thermoelectric converters (20; 120) has its first surface (20a; 120a) in direct contact with the first heat exchange fluid (C).