a-5d is a diagrammatic illustration of the method of making a thermoelectric element;
a illustrates a cross-sectional view of one embodiment of the thermoelectric element along plane 6a-6a in
b illustrates a cross-sectional view of another embodiment of the thermoelectric element.
The thermoelectric module 100 used within an HVAC system 300 acts as a heat pump. In such an application, electric power is supplied to the thermoelectric module 100. The current drives a transfer of heat from one end of the thermoelectric module 100 to the other, creating a hot region 125 and a cold region 150. The cold region 150 may be used to cool, or the hot region 125 may be used to warm other parts or systems of the machine 900. For example, the cold region 150 can be used to cool air in a HVAC system, and the hot region 125 can be used to warm oil or fuel. The thermoelectric module 100 may comprise several thermoelectric devices 50.
Although the thermoelectric module 100 is described for application in an exhaust system 400 and an HVAC system 300 of the machine, these descriptions are illustrative only. It is understood that the thermoelectric module 100 can be used anywhere where heat energy is to be converted to electrical energy or where electrical energy is to be used to create a temperature differential between two regions.
The top and bottom cover tabs 24, 22 may be attached to the bottom of the cavities 44 using an adhesive (not shown), or it may be coated to the bottom surface of the cavity 44. Any electrically conductive adhesive 10 known in the art may be used to connect the thermoelectric elements 20, 30 to the top and bottom cover tabs 24, 22 and any common adhesive known in the art can be used to attach the tabs 22, 24 to the top and bottom cover plates 6, 4. For example, phosphate binders, metal filled epoxies, metal pastes, or high temperature solders or any other adhesive which is electrically conductive may be used as the electrically conductive adhesive 10, and any adhesive epoxies or glue may be used to attach the tabs 22, 24 to the bottom of the cavities 44. Any electrically conductive material, such as nickel, copper, or aluminum, can be used as the tabs 22, 24. If a coating process is used to form the tabs 22, 24 at the bottom of the cavities 44, any coating technique known in the art, such as plating, sputtering, etc., may be used.
The top and bottom cover tabs 24, 22 are used to electrically interconnect the n-type and p-type thermoelectric elements 30, 20 serially. A bottom cover tab 22 may electrically connect the bottom terminal 18 of one of the n-type thermoelectric elements 30 to the bottom terminal 18 of an adjacent p-type thermoelectric element 20. A top cover electrically conductive tab 24 may electrically connect the top terminal 16 of the same p-type thermoelectric element 20 to the top terminal 16 of a different adjacent n-type thermoelectric element 30. The bottom terminal 18 of this n-type thermoelectric element 30 may then be connected to the bottom terminal 18 of a different adjacent p-type thermoelectric element 20. This interconnection pattern may be repeated until all the n-type and p-type thermoelectric elements 30, 20 are connected together serially. At least two electrically conductive leads 26 may electrically connect to the interconnected thermoelectric elements, and extent outside the housing. Other interconnection schemes may also be used to interconnect the n-type and p-type thermoelectric elements 30, 20.
A housing 8 may enclose the top and bottom cover plates 6, 4, the plurality of n-type and p-type thermoelectric elements 30, 20, and the top and bottom terminals 16, 18 to protect it from pollutants, and increase the structural robustness of the device. In some applications, the housing 8 may also be used to seal the enclosed elements in a vacuum. Although the housing 8 is shown as substantially enclosing the other components of the thermoelectric device 50, the housing 8 can be of any form or, in some applications, be eliminated.
a, 5b, 5c, and 5d, illustrate the method of making a p-type thermoelectric element 20. Thermoelectric material 62 of p-type, is deposited on low-cost high temperature flexible substrate 60 with low thermal and electrical conductivities. Such a substrate could include any polyamide, Kapton® tape or any other suitable flexible substrate. Any deposition technique, for example sputtering, can be used to deposit the thermoelectric material 62 on the substrate 60. Any thermoelectric material can be deposited on the flexible substrate 60 to act either as a p-type or n-type thermoelectric element. For example, different stochiometries of boron carbine, silicon carbide, silicon germanium, bismuth telluride, germanium telluride, or any other thermoelectric material known in the art may be used as the thermoelectric material 62. These materials can also have any structure including zero-dimensional quantum dots, one-dimensional nano wires, two-dimensional quantum well and superlattice thermoelectric structures. The thermoelectric material 62 deposited on the flexible substrate 60 together constitute the thermoelectric film 64. The thermoelectric film includes two pairs of opposite edges—a first edge 66, a second edge 68, a third edge 67 and a fourth edge 69. The p-type thermoelectric element 20 is formed by winding the thermoelectric film 64 around a support structure which may have low thermal and electrical conductivity. The support structure may have any form. For example, the support structure have the form of a hollow tube 72. Hereinafter, the support structure will be described as a hollow tube 72. Such a hollow tube 72 may be formed of, for example, alumina or other suitable materials.
As shown in
b is an illustration of the p-type thermoelectric element 20 after completion of the winding and attachment process described above. The thermoelectric element 20 may then be cut into multiple pieces of desired lengths. These pieces could be of the same or different lengths.
c is an illustration of the thermoelectric elements that have been cut to a desired length. Any cutting process known in the art, such as water jet cutting, laser cutting, diamond saw cutting or any other cutting technique can be used. An alternative method of forming the elements illustrated in
The top and bottom terminals 16, 18 may be formed by coating the top and bottom end surfaces 12, 14 of the p-type thermoelectric element 20.
a is a cross-sectional illustration of the p-type thermoelectric element 20 along plane 6a-6a of
In an alternative embodiment, illustrated in
Both the n-type and the p-type thermoelectric elements 30, 20 may be formed in the same manner as described above, except that a thermoelectric material 62 of n-type is deposited on the flexible substrate 60 to form the thermoelectric film 64 of n-type. The thermoelectric film 64 of n-type may then be wound around and attached to a hollow tube 72, and its parallel end surfaces 12, 14 coated with the terminals 16, 18 as described above.
The thicknesses of the flexible substrate 60 and thermoelectric material 62 can be any value that will provide adequate structural support, without cracking when the thermoelectric film 64 is wound around the hollow tube 72. For some applications within a machine, the thickness of the flexible substrate 60 may be between approximately 7 and 30 microns, and the thickness of each deposited layer of the thermoelectric material 62 may be between approximately 2 and 10 microns. The size of each cylindrical thermoelectric element 20, 30 may be between approximately 0.5 and 1 centimeter in diameter, and approximately 2.5 and 4.5 centimeters in height. The dimensions described in this paragraph are illustrative only. It is understood that the required power, in the case of power generation application, or the required temperature in the case of heat pump applications will dictate the physical size of the cylindrical thermoelectric elements 20, 30.
Any sequence of operations may be used to assemble the thermoelectric device 50. One suitable technique to assemble the thermoelectric device 50 is described below. A conductive adhesive 10 may be placed in the cavities 44 of the bottom cover plate 4. The thermoelectric elements 20, 30 may then be placed on the conductive adhesive 10 in the cavities 44 such that the bottom end surface 14 of the thermoelectric elements 20, 30 are substantially parallel to the bottom of the cavities. The thermoelectric elements 20, 30 may also be individually attached to the bottom of the cavities 44 using conductive adhesive 10, as depicted in
The disclosed thermoelectric device 50 may be applicable to any machine including a fixed or a mobile machine that performs any type of operation. For example, the thermoelectric device 50 may be used in association with an industry such as mining, construction, farming, transportation, aerospace or any other industry known in the art. The disclosed thermoelectric device 50 with n-type and p-type thermoelectric elements 30, 20 can be used to generate power from waste heat that is a byproduct of machine operation. The power produced by the thermoelectric device 50 can be used to assist in the driving of any system of the machine, decreasing the fuel consumed by the machine, and thereby increasing its efficiency. The disclosed thermoelectric device 50 with n-type and p-type thermoelectric elements 30, 20 can also be used as a heat pump to cool or heat an object.
When the thermoelectric device 50 is used in a module used to generate power, the thermoelectric device 50 converts thermal energy from a temperature gradient between a hot region and a cold region into electrical energy utilizing the Seebeck effect. When the thermoelectric device 50 is used as a heat pump, it converts electrical energy into a temperature gradient utilizing the Peltier effect. The absence of moving parts in the thermoelectric device will make such a power production thermoelectric device or a heat pump reliable and quiet. The operation of thermoelectric device 50 with n-type and p-type thermoelectric elements 30, 20 will now be explained.
During operation of machine 100, waste heat, either in the form of hot exhaust gases or hot surfaces, produce a hot region. Thermoelectric devices 100 are arranged such that one of the cover plates 4, 6 are in thermal contact with the hot region, and the other cover plate in thermal contact with a cooler region. The cooler region can be any surface of the machine that has a temperature lower than the hot region, for instance a heat exchanger, or atmospheric air. Since the opposite end surfaces 12, 14 of the thermoelectric elements 20, 30 are in contact with opposite cover plates 4, 6, a temperature differential is created between the two junctions of the thermoelectric elements 20, 30. P-type thermoelectric elements 20 are those which are created using p-type thermoelectric materials 62 where the primary charge carriers are holes, and n-type thermoelectric elements 30 are those where the primary charge carriers are electrons. Thermoelectric materials can produce a voltage potential in the presence of a temperature gradient across the thermoelectric materials and, alternately, can produce a temperature gradient in response to an applied voltage potential. The magnitudes of the temperature gradient and the voltage may be proportionally related. When p-type and n-type thermoelectric elements 30, 20 are connected electrically in series and thermally in parallel, with one junction in the hot region and the other at the cold region, a potential difference is created due to the Seebeck effect. The potential difference generates a current when connected to an electrical load. Electrically conductive leads 26 conduct the power generated by the thermoelectric device 50 to outside the housing 8. If multiple thermoelectric devices 50 are present in thermoelectric module 100, the leads 26 of multiple thermoelectric devices 50 may be connected together, to combine the power produced by all the thermoelectric devices 50 to do useful work in the machine.
When the thermoelectric modules 100 are used as a heat pump, the electrically conductive leads 26 are used to supply power to the thermoelectric device 50 from outside the housing 8. This electric power, establishes current flow through the n-type and p-type thermoelectric elements 30, 20. When a current is passed through n-type and p-type thermoelectric elements 30, 20 that are connected to each other at two junctions, a flow of electrons and holes are established. The electrons move from the n-type to the p-type material and the holes from the p-type to the n-type material through the top and bottom cover tabs 24, 22. The charge carriers jump to a higher energy state absorbing thermal energy at the cold side and drops to a lower energy state releasing energy as heat to the hot side. This transfer of heat causes one junction to cool and the other junction to heat up. The hot end may be used to heat parts of the machine that need heating, and the cool end may be used to cool parts that need cooling.
One n-type and one p-type thermoelectric element 20, 30 constitute a thermoelectric couple. The thermoelectric device 50 can include one or more thermoelectric couples depending upon the performance requirements. The thermoelectric elements are formed by blanket deposition of the thermoelectric material 62 over a thin film substrate 60, thereby avoiding masking and deposition operations. The power produced by thermoelectric elements can be increased by increasing the cross-sectional area of the thermoelectric material 62 available for heat flow. The cross-sectional area of the thermoelectric material 62 available for heat flow corresponds to the area of the thermoelectric material 62 exposed in
Low conductivity tubes are used instead of solid bars to increase the thermal resistance of the center support, and to force most of the heat to flow through the thermoelectric material. It will be apparent to those skilled in the art that various modifications and variations can be made to the disclosed thermoelectric device 50. Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice of the disclosed thermoelectric device 50. It is intended that the specification and examples be considered as exemplary only, with a true scope being indicated by the following claims and their equivalents.
This invention was made with government support under the terms of Contract No. ZCL-4-32060-04 awarded by the Department of Energy. The government may have certain rights in this invention.