Thermoelectric Device With Patterned Substrate For Waste Heat Recovery
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Solution Overview
Problem
Waste heat generated by various devices and machines, such as solar cells, is not effectively recycled, leading to energy loss, and existing thermoelectric devices do not provide a practical solution for harnessing this heat.
Innovation Solution
A photovoltaic-thermoelectric module is designed with a patterned glass substrate featuring peaks and valleys, where different film compositions are coated on each surface to form interfaces that generate a voltage proportional to temperature differences, allowing the thermoelectric device to be coupled with heat source devices to convert waste heat into electricity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a combined solar cell/thermoelectric device is provided to recycle waste heat, then energy efficiency is improved, but device complexity increases
Solution Approach 1:
The patent combines a photovoltaic device and a thermoelectric device into a single integrated module. The thermoelectric device is positioned adjacent to the rear face of the photovoltaic device, allowing the hot side of the thermoelectric device to contact the photovoltaic device while the cold side is exposed to ambient air or cooling. This merging enables simultaneous electricity generation from both sunlight (photovoltaic effect) and waste heat (thermoelectric effect), resolving the contradiction by reducing energy loss without requiring entirely separate systems.
Solution Approach 2:
The integrated module serves multiple functions: the photovoltaic device converts solar radiation to electricity during daytime, while the thermoelectric device recovers waste heat from the photovoltaic device's rear face. The same structure provides both photovoltaic power generation and thermoelectric waste heat recovery, making the system multi-functional and improving overall energy utilization without proportionally increasing complexity.
2Productivity
If conventional thermoelectric devices are used with solar cells, then energy recovery is improved, but manufacturing complexity increases
Solution Approach 1:
The thermoelectric device is segmented into multiple independent thermocouples, each consisting of n-type and p-type semiconductor legs arranged in series. This segmentation allows for modular manufacturing where individual thermocouples can be produced separately and then assembled into the complete thermoelectric device, simplifying the overall manufacturing process while maintaining high energy recovery efficiency.
Solution Approach 2:
The thermoelectric device uses composite structures combining n-type and p-type semiconductor materials with metal electrodes and ceramic substrates. These composite materials and structures are designed to optimize thermal and electrical properties while facilitating standardized manufacturing processes. The use of commercially available semiconductor materials and standard assembly techniques improves ease of manufacture while achieving effective energy recovery.
3Temperature
If the thermoelectric device contacts the photovoltaic device at multiple points, then heat transfer is improved, but device complexity increases
Solution Approach 1:
Instead of using multiple discrete contact points that would increase structural complexity, the patent employs a continuous planar contact surface where the hot side of the thermoelectric device contacts the rear face of the photovoltaic device over an extended area. This dimensional approach distributes heat transfer across a surface rather than through scattered points, improving thermal efficiency while maintaining a simple, straightforward structural arrangement.
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 module effectively converts temperature differences into electricity, enhancing energy recovery from heat source devices by creating a voltage proportional to the temperature gradient, thereby reducing waste heat and improving overall energy efficiency.
Implementation Method 1
The thermoelectric effect is well known. It involves converting a temperature difference into an electric voltage, or vice versa. When a thermoelectric device has two sides at different temperatures (i.e., a hot side and a cold side), the device creates a voltage.
Implementation Method 2
the photovoltaic device includes a front face and an opposed rear face, the front face being adapted to receive incident solar radiation
Data Source
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AI summary
A thermoelectric device for use with solar cells or other heat sources. A substrate has a manufactured surface with a plurality of highland features and lowland features. Each highland feature defines a peak adjacent to which there is an interface of two different film regions (formed of two different metals, two different semiconductors, or one metal and one semiconductor). The two film regions diverge away from each other with increasing distance from the interface and terminate at distal end regions. In response to a temperature difference between the interface and the distal end regions, the device produces a voltage.