Thermoelectric Generator Embedded in Thermal Insulation
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Solution Overview
Problem
Industrial thermoelectric generators face inefficiencies due to the need for thermal insulation, which inhibits heat flow and reduces the thermal gradient, making it cost-prohibitive to convert wasted thermal energy into electricity effectively.
Innovation Solution
A thermoelectric generation assembly with thermally insulative materials surrounding thermoelectric elements, allowing them to be embedded in industrial processes while maintaining thermal insulation, converting process heat into electricity by arranging multiple elements in series and using suitable insulation materials like ceramics or polymers to manage heat flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermal insulation is provided to inhibit unwanted heat flow, then process efficiency and safety are improved, but heat flow to thermoelectric generator is reduced and generation efficiency deteriorates
Solution Approach 1:
The patent combines the thermal insulation function with the electricity generation function by integrating thermoelectric generator elements directly into the insulation structure. The insulation material serves dual purposes: preventing unwanted heat loss while simultaneously enabling thermoelectric power generation through the thermal gradient that naturally exists across the insulation layers.
Solution Approach 2:
The insulation structure is designed to perform multiple functions: it provides thermal insulation to maintain process safety and efficiency, while also serving as the heat flow path for thermoelectric generators to produce electricity. This multi-functional design eliminates the need for separate insulation and power generation systems.
2Loss of energy
If thermoelectric generator is applied to convert wasted thermal energy to electricity, then energy reclamation is improved, but thermal insulation requirements conflict with heat flow needs
Solution Approach 1:
The patent merges the insulation layers with thermoelectric generator modules into a single integrated structure. Instead of adding separate thermoelectric devices to existing insulation, the generators are embedded within the insulation layers themselves, creating a unified component that addresses both energy recovery and insulation needs.
Solution Approach 2:
The insulation structure is designed to simultaneously provide thermal isolation and enable energy conversion. The same material layers that prevent heat loss also serve as the thermal pathway for thermoelectric power generation, eliminating the need for separate systems and reducing overall complexity.
3Power
If multiple thermoelectric elements are wired in series to increase power output, then electricity generation capability is improved, but device complexity increases
Solution Approach 1:
The thermoelectric generator is divided into multiple discrete elements or modules that can be independently manufactured and then connected in series. Each element contains thermoelectric couples embedded in insulation layers, and these modular units are stacked or connected to achieve the desired power output while maintaining manufacturing simplicity.
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 solution enables the efficient conversion of wasted thermal energy into substantial industrial power while providing thermal insulation, increasing process efficiency and reclaiming lost energy, as demonstrated by the generation of 1.83 kilowatts of power from a matrix of thermoelectric modules.
Implementation Method 1
Thermoelectric materials, in accordance with known physical concepts, generate an electrical current flow in response to a thermal gradient across the thermoelectric generator
Implementation Method 2
A thermally insulative material surrounds the lateral surface of each thermoelectric element
Data Source
AI summary
An industrial thermoelectric generation assembly and method are provided. A plurality of thermoelectric generation elements is provided. Each element has a first side, a second side opposite the first side, and a lateral surface. A thermally insulative material surrounds the lateral surface of each thermoelectric element. The first side of each thermoelectric element is disposed to contact a process heat source, and the second side is configured to be exposed to an ambient environment. At least two of the plurality of thermoelectric generation elements are wired in series. The thermoelectric generation elements, being good thermal insulators, provide good thermal insulation to the process. Withholding heat within the process (which is desired), is converted to electricity.