This application relates to power generation using thermoelectric generators and, more particularly, to power generation using a thermoelectric generator and a phase change material.
Energy harvesting devices generate electrical power from energy sources that are often overlooked and untapped. Examples of energy sources and methods to convert electricity include photovoltaic devices which convert light energy into electricity, cantilevered piezoelectric beams which convert vibrational energy into electricity and thermoelectric devices which convert heat flow into electricity. These energy harvesting devices and methods are amenable to a variety of applications.
As low power electronics become increasingly prevalent, energy harvesting devices and methods provide a useful way to power electronic devices without the need for batteries or even electrical power wiring. Electrical wiring is undesirable in many applications due to its cost to design and install, as well as its weight and difficulty to retrofit. Batteries are undesirable on airplanes, for example, due to the difficulty of replacement and because some batteries pose environmental or safety hazards. Additionally, batteries may function poorly in low temperatures. In some cases, electronic devices that occasionally require medium quantities of electrical power may be powered using low-power energy harvesting devices. In these cases, electrical energy generated by energy harvesting devices is stored in a capacitor or rechargeable battery.
Thermoelectric generators are devices that utilize the physics principal known as the Seebeck effect discovered in 1821. If two conductors of different materials such as copper and iron are joined at their ends forming two junctions, and one junction is held at a higher temperature than the other junction, a voltage difference will arise between the two junctions. Various thermoelectric generators are commercially available. One such module is an HZ-2 from Hi-Z Corporation. The dimensions of the module are 1.15 inches×1.15 inches×0.20 inch, and the module comprises a 14×14 array of thermoelectric elements.
In one aspect, an energy harvesting device is disclosed that includes a thermoelectric device adapted to produce electricity according to a Seebeck effect when a thermal gradient is imposed across first and second major surfaces thereof, a housing enclosing a phase change material that is disposed for thermal communication with the first major surface of the thermoelectric device for thermal communication between the phase change material and the thermoelectric device, and a radio transmitter electrically coupled to the thermoelectric device. The radio transmitter is capable of transmitting signals.
In another aspect, an energy harvesting device is disclosed that includes a thermoelectric device adapted to produce electricity according to a Seebeck effect when a thermal gradient is imposed across first and second major surfaces thereof, a housing enclosing a phase change material that is disposed for thermal communication with the first major surface of the thermoelectric device, and a conductive fin within the housing to provide more uniform distribution of heat within the phase change material.
Any of the embodiments disclosed herein for the energy harvesting devices may be mounted to a substrate that is part of a mobile device that experiences a temperature change as a result of its mobility.
The features, functions, and advantages that have been discussed can be achieved independently in various embodiments or may be combined in yet other embodiments, further details of which can be seen with reference to the following drawings and description.
The following detailed description will illustrate the general principles of the invention, examples of which are additionally illustrated in the accompanying drawings. In the drawings, like reference numbers indicate identical or functionally similar elements.
Referring initially to
The temperature variation that the thermoelectric device 20 is exposed to may be a result of the mobility of a substrate 24 to which the thermoelectric device 20 is thermally conductively mounted. In one embodiment, the substrate 24 may be part of a mobile vehicle such as an aircraft. The substrate 24 may be an aircraft wall that will experience a temperature change during take off, flight, and/or landing. Generally, the aircraft wall includes an interior panel, an outer aircraft skin, and a wall space between the interior panel and the aircraft skin. The energy harvesting device 10 may be thermally conductively mounted to any one of these layers.
An aircraft may experience a temperature change from ambient air temperature on the ground to about −28° C. during flight. Temperature variations may also exist at other aircraft structural components, for example, but not limited to hydraulic lines (typically temperatures of about 20° F. to about 200° F. above ambient temperature), engines, PAC bleed air ducts (typically at temperature of about 490° F.), during ground operations, or while the aircraft is parked. Any of these temperature variations may be taken advantage by the energy harvesting devices 10, 10′ as long as the materials selected for the device's construction will not degrade, react, or fail at such temperatures. The devices 10, 10′ should also be capable of harvesting energy during a phase change transition at some commonly experienced mid-range temperature.
While an aircraft is used as an example of a mobile vehicle to which the energy harvesting devices 10 may be mounted, “mobile vehicle” is not limited thereto. The mobile vehicle may be a ship, submarine, automobile, train, projectile, balloon, animal, or spacecraft.
The energy harvesting devices 10 as shown in
The thermoelectric device 20 may be any known and/or commercially available device such as a Thermoelectric Generator or the like available from Hi-Z Technology, Inc., EnOcean GmbH, and/or Micropelt GmbH. In one embodiment, the thermoelectric device 20 may include a BiSn junction on an alumina ceramic material. One aspect of the energy harvesting devices 10, 10′ is to miniaturize the devices. Accordingly, the thermoelectric device 20 is as small as possible and may be at most about 2.5 mm×3.3 mm×1.1 mm. In another embodiment, the thermoelectric device 20 may be at most about 3.4 cm×3.0 cm×1.0 cm.
To enhance thermal conductivity between the thermoelectric device 20 and the surfaces its two major surfaces 40, 42 contact, thermally conductive layers 18, 18′ may be present thereagainst. As shown in
Still referring to
Referring now to
In an alternate embodiment as shown in
In one embodiment, the open-cell, conductive foam is a carbon foam. The carbon foam may be a graphene foam. One exemplary commercially available foam is KFOAM carbon foam, available from Thomas Golubic at GolubicTA@koppers.com. KFOAM has highly ordered graphitic ligaments for high thermal conductivity greater than 100 W/m·K, similar to aluminum, but with one-fifth the density (density range of 0.35-0.60 g/cc) and has a coefficient of thermal expansion that is close to silicon. The open porosity of the carbon foam is about 75-80 percent. KFOAM has a compressive strength of 3.5 MPa, and is able to perform as a stand-alone material or bonded to other materials to enhance their properties. The carbon foam also has uniform density throughout that results in more consistent machining with less waste. Accordingly, KFOAM can easily be cut into various shapes and configurations.
The housing 12 may be capable of housing about one microliter up to about 1000 ml, more particularly a half a milliliter to about 20 ml of the PCM 14, but is not limited thereto. In one embodiment, the housing may house up to about 2 ml of a PCM 14.
Within the housing 12, as shown in
By way of example here, the substrate 24 is part of an airplane structure. The substrate's temperature changes as it becomes exposed to portions of the atmosphere at various temperatures. For example, when an airplane climbs from one altitude to a substantially different altitude, the structure is exposed to different parts of the atmosphere that are typically colder at the higher altitudes and warmer at lower altitudes. Therefore, the structure's temperature will vary substantially. It may vary, for example, from 50° F. when the airplane has been sitting at an airport to −25° F. after it has climbed to a cruise altitude.
In this example, heat will transfer out of the water 14, through the container 12, TEG 20 and substrate 24 and into the atmospheric air 46. This loss of thermal energy out of the water 14 will eventually bring the water down to the freezing point, where it will go through a phase change, and then continue down to a temperature approaching that of the substrate (e.g. −25° F. in this example).
This onset of phase change is where the two devices 10, 10′ begin to differ. The water in device 10′ will start to solidify from the coldest surface first, which is the surface nearest the TEG 20 since this is the surface from which heat is being more significantly lost. As ice builds on this surface, the solid ice is capable of supporting a temperature gradient through its thickness, x′, with its surface at the liquid/solid interface at freezing (−32° F.) and its surface closest to the generator now at some temperature below freezing. Thus, the temperature gradient across the TEG 20 of device 10′ (ΔT′=T2′−T1′) begins to decline.
In device 10, the internal fins 16 are able to draw heat deeper within the phase change material 14. Thus, the buildup of the solid phase of the PCM (ice for this example) will be spread over the larger surface area of the fins 16 and be substantially thinner, x, than the thickness, x′, of the ice in device 10′. The thinner ice build-up of device 10 will support a smaller temperature gradient, thus allowing temperature T2 to be higher than T2′ at the surface of the TEG 20. This higher temperature in device 10 provides a higher temperature gradient across the TEG 20 thereof (ΔT=T2−T1>ΔT′=T2′−T1′). As shown in
TEGs 20 provide voltages that are proportional to the temperature gradient across their surfaces. Accordingly, the voltages in device 10 will be higher than the voltages in device 10′, thus providing superior performance.
Energy harvesting device 10 has additional thermal advantages over device 10′ as shown by the thermal circuit diagram 50 in
Given that T3,T3′=32° F., T1,T1′=−25° F. and that Rcontainer and RTEG are the same in both designs, Rice is the only variable governing the temperatures at T2 and T2′. As Rice is proportional to thickness x, device 10 will clearly produce a higher temperature gradient across the TEG than device 10′, given the relationship
The fin 16 as shown in
The fins 16 may be or include the same or a different conductive material as the housing 12. In one embodiment, the fins 16 may be of a construction that provides greater surface area for thermal contact with the PCM 14. In one embodiment, the fins 16 may be an open-cell, conductive foam 62 as shown in the energy harvesting device 60 of
The phase change material 14 housed within the housing 12 of the energy harvesting device 10 and in contact with fins 16 may be any suitable phase change material for the temperature variation that will be experienced by the substrate 24. In one embodiment, the PCM 14 present in the energy harvesting device 10 is one that will respond to the temperature in the midrange of the thermal cycles experienced by the substrate 24 during the mobile vehicle's intended use. An advantage provided by the PCM 14 is that it extends the time of thermal differential across the TEG during surface temperature fluctuations so as to increase the amount of thermoelectric energy harvested. In one embodiment, the PCM 14 transitions from a liquid to a solid and from solid to liquid.
Water is one example of a PCM. Water requires a removal of 334 joules/gram to make the phase change from water to ice and conversely the addition of 334 joules/gram to change from ice back to water. In one embodiment, another PCM may be mixed with the water.
Other suitable PCMs include organic PCMs such as but not limited to lauric acid, trimethylolethane (about 37 wt % water), heptanone-4, n-undecane, TEA-16, ethylene glycol, n-dodecane, thermasorb 43, thermasorb 65, sodium hydrogen phosphate, thermasorb 175+, and thermasorb 215+ and inorganic PCMS such as but not limited to Mn(NO3)2.6HOH+MnCl2.4HOH, sodium silicate, zinc, aluminum. The PCM may also be a metallic PCM including binary and ternary eutectic systems. Some example metallic PCMs are present in Table 1 below.
As TEGs 20 in the energy harvesting devices 10, 10′ typically produce relatively low voltages, a voltage boosting circuit 26 may be electrically coupled to the energy harvesting devices 10, 10′ to produce a voltage useful for the electrical load of a selected end device. Experimentation shows, for example, that typical TEG's as used in the above described energy harvesting devices 10, 10′ produce on the order of 0.5 V open circuit. A voltage boosting circuit 26 can boost the voltage to something on the order of 4.5 V. 4.5 V is sufficient to charge small batteries or a capacitor as part of a wireless sensor node. The voltage boosting circuit's efficiency is often related to its input voltage (everything else being equal); accordingly, device 10 of
The higher temperature gradient across the TEG 20 results in an increase in the voltage produced by the energy harvesting device 10. Accordingly, the presence of the conductive fin(s) and, optionally, the voltage boosting circuit may increase the overall energy generated by the TEG 20 by about 20 to about 40%.
In one embodiment, the voltage boosting circuit 26 may be electrically coupled to a radio transmitter 30. The radio transmitter may include an energy storage device 32 such as a capacitor to store energy from the voltage boosting circuit 26. The energy stored within the radio transmitter 30 that ultimately came from the energy harvesting device 10, 10′ may be sufficient to trigger multiple transmission from the radio transmitter to send signals 38.
Instead of radio transmitter 30, an independent energy storage device (not shown) may be electrically connected to the thermoelectric device 20 to receive and/or store the electrical power therefrom. The stored electrical power can be used to power various electrical devices such as dimming windows or sensors. In another embodiment, the thermoelectric device 20 or the voltage boosting circuit 26 may be directly connected to an electrical device for powering that electrical device, which is typically through wiring. In typical applications, energy harvesting devices 10 are provided in multiple locations on mobile device (e.g., throughout the fuselage of an aircraft) to ensure an adequate supply of electrical power to the chosen electrical device or devices.
In one embodiment, the electrical device that is the ultimate recipient of the power from the energy harvesting device 10 is a sensor. The sensor may be a wireless sensor; thus, the presence of the radio transmitter 30 is required. Wireless sensors are particularly useful in the wing, tail or landing gear bay of an aircraft, where the addition or retrofit of wires would be difficult. For example, the energy harvesting device 10 is well-suited to flight test or health monitoring applications to report the position of an actuator or temperature of a surface without the need to extend a length of wiring to the monitored device. Energy levels as low as 50 joules per flight cycle could be useful to sustain the lowest-power wireless sensors. An example sensor may be one that wakes once per hour or upon a triggering event, samples a sensor transducer, and logs the data in non-volatile memory for later retrieval.
The embodiments of this invention described in detail and by reference to specific exemplary embodiments of the energy harvesting device and methods are within the scope of the appended claims. It is contemplated that numerous other modifications and variations of the energy harvesting device and methods may be created taking advantage of the disclosed approach. In short, it is the applicants' intention that the scope of the patent issuing herefrom be limited only by the scope of the appended claims.