Tubular Thermoelectric Module Segmentation for Cost-Efficient Series Production
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Solution Overview
Problem
Existing thermoelectric generators for motor vehicles are expensive to produce and have low efficiency, making them unsuitable for series production.
Innovation Solution
A tubular thermoelectric module design featuring alternating n-doped and p-doped semiconductor elements connected by electrically conductive first and second connections, allowing for cost-effective production and simple interconnection of modules, with a method involving the use of inner and outer tubes and semiconductor elements arranged in a specific configuration to facilitate series and parallel connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional thermoelectric generators are used for motor vehicles, then thermal energy can be converted into electrical energy, but the production cost is very high and efficiency is relatively low
Solution Approach 1:
The thermoelectric generator is divided into multiple independent modules, each containing a specific number of thermoelectric elements (e.g., 8 elements per module). This segmentation allows for standardized mass production of individual modules, reducing overall manufacturing complexity and cost while maintaining efficient energy conversion through optimized element arrangement within each module.
Solution Approach 2:
Multiple thermoelectric elements are combined within each module housing, with alternating n-type and p-type elements arranged in series. This merging of multiple elements into integrated modules achieves economies of scale in production while the series connection configuration maximizes voltage output and conversion efficiency.
2Productivity
If conventional thermoelectric modules are produced, then electrical energy can be generated from exhaust gas, but the modules are expensive and not suitable for series production
Solution Approach 1:
The system is segmented into standardized modules that can be independently manufactured and then assembled in series to meet different power requirements. Each module contains a fixed configuration of thermoelectric elements and housing, allowing for repetitive manufacturing processes that reduce costs and improve productivity through economies of scale.
Solution Approach 2:
The invention optimizes key parameters including the arrangement of thermoelectric elements (alternating n-p-n-p sequence), the configuration of electrical connections (series wiring within modules), and the modular housing design. These parameter changes enable standardized production processes that significantly reduce manufacturing costs while improving suitability for series production.
3Loss of energy
If thermoelectric elements are arranged in alternating n-doped and p-doped sequence, then electrical energy generation efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The alternating n-p-n-p element sequence is implemented within standardized module configurations (e.g., 8 elements per module), which segments the complex alternating pattern into manageable, repetitive units. This segmentation maintains the efficiency benefits of alternating doping sequences while reducing manufacturing complexity through standardization.
Solution Approach 2:
The thermoelectric elements are pre-assembled into complete modules with all electrical connections (series wiring between adjacent elements) established during module manufacturing. This preliminary assembly of complete functional units simplifies subsequent system integration and reduces overall manufacturing complexity while preserving the efficient alternating element configuration.
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 the production of cost-effective thermoelectric modules that can be easily interconnected, improving efficiency and suitability for series production, thereby enhancing the energetic efficiency of motor vehicles by effectively converting thermal energy into electrical energy.
Implementation Method 1
Thermoelectric materials are of such a type that they can effectively convert thermal energy into electrical energy (Seebeck effect)
Implementation Method 2
Thermoelectric materials are of such a type that they can effectively convert thermal energy into electrical energy (Seebeck effect) and vice versa (Peltier effect)
Data Source
AI summary
A method for producing a thermoelectric module and a tubular thermoelectric module include at least an inner tube, an outer tube and an interspace therebetween. At least a plurality of rings each formed by a plurality of n-doped and p-doped semiconductor elements disposed alternately in a circumferential direction are disposed in succession in an axial direction of the thermoelectric module in the interspace. On an inner side or an outer side of the semiconductor elements of one ring, electrically conductive first connections run only in the circumferential direction and, on an opposite outer side or inner side, at least one electrically conductive second connection electrically conductively connects an n-doped to a p-doped semiconductor element of an adjacent ring and runs at least in the axial direction of the thermoelectric module.