Thermoelectric Generator Module With Nested Tubes
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Solution Overview
Problem
Existing thermoelectric generators for motor vehicles are costly and large, making them incompatible with series production and requiring comprehensive changes to existing vehicle concepts, with issues in fluid and coolant separation and electrical contacting leading to power loss and maintenance challenges.
Innovation Solution
A module for a thermoelectric generator with a tube-like construction featuring inner and outer metallic tubes, thermoelectric elements between them, and electrically conductive contacts for efficient energy generation, along with compensation elements for thermal expansion and sealing to prevent corrosion and short-circuits, allowing for compact integration and low power loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional thermoelectric generators are used for motor vehicles, then energy conversion from exhaust gas heat to electrical energy is achieved, but the device becomes large and costly, making it incompatible with series production
Solution Approach 1:
The thermoelectric generator is divided into multiple modular converter elements, each containing a specific number of thermoelectric elements arranged in series. This segmentation allows for compact integration while maintaining the required electrical output, resolving the contradiction between energy conversion efficiency and overall device size
Solution Approach 2:
The patent implements a nested structure where converter elements are integrated within the exhaust gas system architecture. The thermoelectric elements are positioned between the exhaust gas flow path and the cooling system, allowing the generator to utilize existing spatial volumes in the vehicle without adding significant external dimensions
2Use of energy by moving object
If conventional thermoelectric generators are used for motor vehicles, then energy conversion is achieved, but comprehensive changes to existing vehicle concepts are required
Solution Approach 1:
The converter element design serves multiple functions simultaneously: it converts thermal energy to electrical energy, acts as a heat exchanger between exhaust gas and coolant, and provides structural integration points for the vehicle's exhaust and cooling systems. This multi-functionality eliminates the need for comprehensive vehicle concept changes
Solution Approach 2:
The patent merges the thermoelectric conversion function with the existing exhaust gas heat exchanger system. The converter elements are integrated into the exhaust manifold or heat exchanger housing, combining previously separate systems (exhaust flow, coolant flow, and electricity generation) into a unified compact assembly
3Power
If conventional thermoelectric generators are used, then electrical energy generation is achieved, but fluid and coolant separation issues lead to power loss and maintenance challenges
Solution Approach 1:
The patent extracts the fluid separation function into dedicated sealing components positioned at the interfaces between converter elements and the housing. These sealing elements are specifically designed to prevent exhaust gas leakage into the coolant circuit, ensuring reliable fluid separation and eliminating a major source of power loss and maintenance issues
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 solution enables a compact, robust, and low-power-loss thermoelectric generator that can be easily integrated into motor vehicles without major changes, providing efficient energy conversion from exhaust gas heat to electrical energy.
Implementation Method 1
Thermoelectric materials are of a type which can convert that actual thermal energy into electrical energy (Seebeck effect)
Implementation Method 2
at least one compensation element is provided in the outer tube for equalizing different expansions of the inner tube with respect to the outer tube
Data Source
AI summary
A module for a thermoelectric generator includes first and second ends, at least one inner tube and one outer tube disposed around the outside of the inner tube and at least one thermoelectric element disposed between the inner and outer tubes. The inner and outer tubes are each electrically insulated from the at least one thermoelectric element. At least one electrically conductive first contact is provided on each of the first and second ends, for electrically conductively connecting the at least one thermoelectric element to an electrical conductor. The module can conduct a fluid or coolant flow through the module from the first end to the second end. An electrical conductor, a thermoelectric generator, a motor vehicle and a method for producing a module, are also provided.