Thermoelectric Generator with Flow Diversion for Exhaust Heat Recovery
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Solution Overview
Problem
Existing thermoelectric generators for converting exhaust gas thermal energy into electrical energy in motor vehicles are expensive and have low efficiency, making them unsuitable for mass production and variable stress conditions.
Innovation Solution
A thermoelectric generator design with a heat exchange section featuring multiple flow paths and thermoelectric elements captively connected to a cooling device, utilizing flow diversion and division to maximize heat exchange area and efficiency, and incorporating a catalytic converter section for enhanced thermal energy conversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional thermoelectric generators are used to convert exhaust gas thermal energy into electrical energy, then electrical energy production is achieved, but manufacturing cost is high and conversion efficiency is low
Solution Approach 1:
The exhaust stream is divided into multiple parallel flow paths, each containing thermoelectric elements. This segmentation allows the thermal energy to be distributed across multiple conversion units, increasing overall efficiency while using simpler, more cost-effective individual elements that can be manufactured separately and assembled.
Solution Approach 2:
The patent introduces a multi-dimensional heat exchange architecture where exhaust gas flows through multiple paths simultaneously, creating a three-dimensional heat transfer network. This dimensional expansion increases the effective heat exchange area and improves thermal energy capture efficiency without requiring larger or more complex single-path designs.
2Productivity
If thermoelectric elements are added to increase conversion efficiency, then electrical energy output improves, but device complexity increases
Solution Approach 1:
The heat exchange sections are designed to serve dual functions: they act as both thermal energy transfer conduits and structural support frameworks for the thermoelectric elements. This multi-functionality reduces the need for separate structural components, simplifying the overall device architecture while maintaining high electrical energy output capacity.
Solution Approach 2:
The patent merges the heat exchange function and the electrical energy generation function into integrated sections where thermoelectric elements are directly mounted on heat exchange surfaces. This consolidation eliminates the need for separate thermal management and power generation subsystems, reducing device complexity while maximizing productivity.
3Loss of energy
If multiple thermoelectric elements are used to improve efficiency, then conversion performance increases, but manufacturing cost increases
Solution Approach 1:
The patent employs multiple identical or near-identical thermoelectric element modules arranged in parallel. These standardized modules can be manufactured using the same processes and then replicated across multiple flow paths. This copying approach maintains high conversion efficiency through multiple elements while achieving cost effectiveness through standardized, repeatable manufacturing.
Solution Approach 2:
The design uses simpler, more cost-effective thermoelectric elements that can be easily replaced if needed, rather than investing in a few expensive, highly efficient elements. This approach prioritizes manufacturing cost reduction while maintaining adequate conversion efficiency through the use of multiple parallel elements.
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 achieves improved efficiency in converting exhaust gas thermal energy into electrical energy, enabling cost-effective mass production and durability under variable engine stresses, while preventing overheating and ensuring reliable operation.
Implementation Method 1
Thermoelectric materials are of a type capable of efficiently converting thermal energy into electrical energy (Seebeck effect)
Implementation Method 2
If a temperature gradient is provided on both sides of the semiconductor blocks, a voltage potential is formed
Data Source
AI summary
A device for producing electrical energy from the exhaust gas of an internal combustion engine, includes a generator with an exhaust gas inlet connection, an exhaust gas outlet connection and at least one heat exchange section therebetween. At least one flow diversion and/or flow division is provided between the exhaust gas inlet connection and the heat exchange section. The heat exchange section has a plurality of flow paths perpendicular to the exhaust gas inlet connection, to be assigned to a plurality of heat exchange units. At least a portion of the heat exchange assembly has at least one thermoelectric element and a cooling device. The at least one thermoelectric element is captively connected to the cooling device. A motor vehicle having the device is also provided.