Multilayer Thermoelectric Generator for Enhanced Temperature Gradient
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Solution Overview
Problem
Existing thermoelectric generators and converters have low efficiency due to single-layer implementations and insufficient temperature differences between thermocouple junctions, limiting the generation of thermo-electromotive force and overall energy conversion efficiency.
Innovation Solution
A thermoelectric generator with a stack of superimposed multistage layers of thermocouples connected in series, featuring alternating rows of hot and cold junctions for enhanced heat exchange and a solar collector for concentrated heat supply, along with a heat removal system to maintain high temperature differences across multiple layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single-layer thermocouple configuration is used, then the device structure is simple, but the temperature difference between junctions is insufficient and the generated thermo-electromotive force is small
Solution Approach 1:
The patent transitions from a single-layer planar configuration to a multilayer stacked configuration, adding the vertical dimension (z-axis) to the thermocouple arrangement. Multiple layers are superimposed with their hot junctions and cold junctions aligned vertically, creating a three-dimensional heat transfer path that maintains large temperature differences while increasing the number of thermocouples and generated power.
Solution Approach 2:
The patent implements a nested structure where multiple thermocouple layers are stacked within each other, with each layer containing hot and cold junctions that are vertically aligned. The layers are arranged concentrically or in a tower configuration, allowing heat to transfer through multiple nested junctions in series, thereby multiplying the thermo-electromotive force while maintaining a compact structure.
2Device complexity
If heat exchange layers are separated by insulator in a multilayer arrangement, then the device can be multilayer, but heat transfer between thermocouple junctions occurs and high temperature gradient cannot be obtained
Solution Approach 1:
The patent removes the insulating layers that separate heat exchange layers in conventional multilayer designs. By extracting the insulation between adjacent thermocouple layers, the patent enables direct thermal contact between the hot junctions and cold junctions of superimposed layers, allowing heat to flow vertically through the stacked junctions without resistance, thereby maintaining a high temperature gradient across all layers.
3Ease of manufacture
If thermocouple junctions are arranged with dielectric substrate and screen printing, then the module can be manufactured, but it is difficult to superimpose other thermocouple layers and heat transfer between layers is limited
Solution Approach 1:
The patent moves from planar screen-printed thermocouples on a dielectric substrate to a vertical stacked configuration where thermocouples are arranged in multiple layers along the z-axis. This dimensional transition allows each layer to be independently manufactured and then stacked, simplifying the superimposition process while enabling efficient vertical heat transfer between aligned junctions without requiring complex lateral routing through dielectric materials.
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
This configuration significantly increases the thermo-electromotive force and efficiency of energy conversion, ensuring reliable operation regardless of external heat sources and weather conditions, with the potential for multiple layers of thermocouples to enhance energy generation.
Implementation Method 1
a solar collector in the form of a parabolic mirror tray that concentrates sunlight
Implementation Method 2
ensuring internal heat exchange between them
Implementation Method 3
flat thermocouples that generate electricity connected in series in electric circuits
Implementation Method 4
heat removal circuit is made in the form of thin metal ribs parallel to each other in one plane on a longitudinal rod
Implementation Method 5
heat removal system to maintain high temperature differences
Data Source
AI summary
A thermoelectric generator consists of circuits arranged in parallel rows, in which thermocouples in adjacent rows are facing each other by the same-named junctions, forming alternating narrow zones of hot and cold junctions. At least one of the layers is a layer of thermal energy thermocouples, the repeatability of the rows of circuits of which is two times less than the repeatability of the rows of circuits of thermocouples generating electricity. Hot and cold zones between the rows of thermocouple circuits of all layers of thermocouples generating electricity and hot and cold junctions of the rows of thermocouple circuits of thermal energy are superimposed, respectively, by tight contact on each other by junctions and substrates, ensuring internal heat exchange between them. In addition, the generator is provided with an external heat supply circuit to the hot zone area and a heat removal circuit from the cold zone area.