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WO2024163685A1 - Thermoelectric generator - Google Patents

Thermoelectric generator Download PDF

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Publication number
WO2024163685A1
WO2024163685A1 PCT/US2024/013897 US2024013897W WO2024163685A1 WO 2024163685 A1 WO2024163685 A1 WO 2024163685A1 US 2024013897 W US2024013897 W US 2024013897W WO 2024163685 A1 WO2024163685 A1 WO 2024163685A1
Authority
WO
WIPO (PCT)
Prior art keywords
planar surface
heat exchangers
manifold
cartridge assembly
fluid path
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2024/013897
Other languages
French (fr)
Inventor
Todd ROOKE
Rich HALVORSON
Dwight Walker
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Synergy Thermogen Inc
Original Assignee
Synergy Thermogen Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Synergy Thermogen Inc filed Critical Synergy Thermogen Inc
Publication of WO2024163685A1 publication Critical patent/WO2024163685A1/en
Priority to MX2025008974A priority Critical patent/MX2025008974A/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • HELECTRICITY
    • H10SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10NELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10N10/00Thermoelectric devices comprising a junction of dissimilar materials, i.e. devices exhibiting Seebeck or Peltier effects
    • H10N10/10Thermoelectric devices comprising a junction of dissimilar materials, i.e. devices exhibiting Seebeck or Peltier effects operating with only the Peltier or Seebeck effects
    • H10N10/13Thermoelectric devices comprising a junction of dissimilar materials, i.e. devices exhibiting Seebeck or Peltier effects operating with only the Peltier or Seebeck effects characterised by the heat-exchanging means at the junction
    • HELECTRICITY
    • H10SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10NELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10N19/00Integrated devices, or assemblies of multiple devices, comprising at least one thermoelectric or thermomagnetic element covered by groups H10N10/00 - H10N15/00

Definitions

  • thermoelectric devices are made from thermoelectric materials that convert thermal energy into electricity. These devices have limited commercial applicability due to high costs and low conversion performance compared with other technologies that accomplish similar energy generation or refrigeration. Due to interest in curbing greenhouse gas emissions and optimizing energy extraction from waste heat, improvements in thermoelectric devices are desired.
  • FIG. 3 is a partially exploded perspective view of a support frame.
  • FIG. 4 is a partially exploded perspective view of a piston assembly.
  • FIG. 6A is a first side view of the cartridge assembly of FIG. 5.
  • FIG. 6B is a second side view of the cartridge assembly of FIG. 5, opposite the first side view of FIG. 6A.
  • FIG. 7 is a top view of the cartridge assembly of FIG. 5.
  • FIG. 8 is a sectional view of the cartridge assembly of FIG. 5, taken along a plane that is orthogonal to a direction of fluid flow within the cartridge assembly.
  • FIG. 11 is a front view of an alternative embodiment of a thermoelectric module assembly.
  • FIG. 1 is a schematic block diagram of a thermoelectric generation system 100.
  • thermoelectric generation system 100 is utilized to generate electricity at oil and gas production facilities. Heat from combustion within a boiler at a facility can be sent to thermoelectric generation system 100 for conversion to electricity.
  • thermoelectric generation system 100 can be coupled with a production facility that heats the gas to reduce emissions of gas into the atmosphere.
  • thermoelectric generation system 100 can be utilized to generate electricity at facilities having an abundance of waste heat.
  • Thermoelectric generation system 100 includes a thermoelectric generator assembly 102, a first fluid side, herein a hot fluid side 104, and a second fluid side, herein a cold fluid side 106.
  • Thermoelectric generator assembly 102 generates electricity from a difference in temperature between hot fluid side 104 and cold fluid side 106.
  • Hot fluid side 104 defines a loop that includes a first thermal heat transfer source, herein a heat source 108, such as a boiler that heats fluid (e.g., a gas or liquid) within the hot fluid side 104.
  • Heat source 108 heats fluid within the hot fluid side 104 to a temperature above 200 degrees Fahrenheit, above 400 degrees Fahrenheit, above 500 degrees Fahrenheit and/or including between 500 to 1,000 degrees Fahrenheit.
  • hot fluid side 104 includes a pump 110 and/or sink 112. Pump 110 carries fluid throughout hot fluid side 104, whereas sink 112 accepts fluid exiting hot fluid side 104. In other embodiments, pump 110 and/or sink 112 can be eliminated. In still further embodiments, multiple pumps 110 can be used.
  • heat source 108 is generated from gas combusted using a boiler such as a low NOx (nitrous oxide) boiler to heat fluid operating above 100,000 British thermal units (BTU), above 250,000 BTUs, above 500,000 BTUs, above 1,000,000 BTUs, and/or including between 1,000,000 BTUs to 10,000,000 BTUs.
  • a boiler such as a low NOx (nitrous oxide) boiler to heat fluid operating above 100,000 British thermal units (BTU), above 250,000 BTUs, above 500,000 BTUs, above 1,000,000 BTUs, and/or including between 1,000,000 BTUs to 10,000,000 BTUs.
  • BTU British thermal units
  • Cold fluid side 106 defines a loop that includes a second thermal heat transfer source, herein a cold source 114, such as a chiller that cools fluid (e.g., a liquid or a gas) within cold fluid side 106.
  • a cold source 114 such as a chiller that cools fluid (e.g., a liquid or a gas) within cold fluid side 106.
  • cold fluid side 106 includes a pump 116 and/or sink 118.
  • Pump 116 (which may include one or more pumps) carries fluid throughout cold fluid side 104, whereas sink 118 accepts fluid exiting cold fluid side 106.
  • the cold fluid side 106 of the thermoelectric generation system 100 can include an ammonia-based fluid that can be activated using the heat returning from the hot side manifold.
  • pump 116 and/or sink 118 can be eliminated.
  • Hot fluid side 104 provides hot fluid to thermoelectric generator assembly 102 through a manifold assembly 120
  • cold fluid side 106 provides cold fluid to thermoelectric generator assembly 102 through a manifold assembly 122
  • Fluid from both manifold assembly 120 and manifold assembly 122 is provided to cartridge assembly 124.
  • cartridge assembly 124 includes one or more hot fluid paths, one or more cold fluid paths, and one or more thermoelectric module assemblies.
  • the thermoelectric module assemblies are positioned adjacent to both a hot fluid path and a cold fluid path and generate electricity based on a difference in temperature between the hot fluid path and the cold fluid path.
  • thermoelectric module assemblies in the form of direct current (DC) can be sent to a power module (or multiple power modules) 126, which in some embodiments includes a controller, DC/DC and DC/AC inverters, battery, and/or other components.
  • Thermoelectric generator assembly 102 in one embodiment, can generate above 2 kilowatts (kW) of electricity, above 5 kWs, above lOkWs, above 25kW, and/or including between 25 and lOOkW.
  • FIG. 2 is a perspective view of an example thermoelectric generator assembly 102.
  • Thermoelectric generator assembly 102 includes a support frame 200 that supports cartridge assembly 124.
  • Support frame 200 is further illustrated in FIG. 3 and includes side supports 254 and 256.
  • Manifold assemblies 258 and 260 are positioned adjacent the frame 200 on either side and are fluidly coupled with the cartridge assembly 124 (e.g., through a plurality of hoses (not shown)).
  • manifold assemblies 258 and 260 can be supported directly by base 204.
  • Manifold assembly 258 includes an ingress manifold 258 A and an egress manifold 258B.
  • manifold assembly 260 includes an ingress manifold 260A and an egress manifold 260B.
  • manifold assembly 258 carries fluid from one fluid side (e.g., hot fluid side 104), whereas manifold assembly 260 carries fluid from the other fluid side (e g., cold fluid side 106).
  • manifold assemblies 258 and 260 can carry fluid from both sides, for example manifold 258A can serve as an ingress manifold for a first side (e.g., hot fluid side 104), with manifold 260B serving as an egress manifold for the first side.
  • manifold 260A can serve as an ingress manifold for a second side (e.g., cold fluid side 106), with manifold 258B serving as an egress manifold for the second side.
  • Cartridge assembly 124 supports a plurality of first side heat exchangers 262, a plurality of second side heat exchangers 264, a plurality of thermoelectric module assemblies 266 and a plurality of power modules 268 receiving electricity from the plurality of thermoelectric module assemblies 266.
  • Each of the plurality of thermoelectric module assemblies 266 is positioned between a respective first side heat exchanger 262 and a respective second side heat exchanger 264.
  • cartridge assembly 124 includes twenty-nine heat exchangers, including fifteen first side heat exchangers 262 and fourteen second side heat exchangers 264.
  • cartridge assembly 124 can include at least five, at least ten, at least fifteen, at least twenty or more than thirty heat exchangers as desired.
  • FIG. 9 is a side view of an example assembly that includes two first side heat exchangers 262 and a second side heat exchanger 264 positioned between the two first side heat exchangers 262.
  • Thermoelectric module assemblies 266 and power module assemblies 268 are positioned on either side of the second side heat exchanger 264.
  • side support 254 includes a plurality of gusset plates or supports 270 supporting a mounting plate 272 and a piston assembly 276 connected to mounting plate 272. Piston assembly 276 interfaces with an outer heat exchanger 282 of the cartridge assembly 124.
  • side support 256 includes a plurality of gusset plates or supports 290 supporting a mounting plate 292 and a piston assembly 296 connected to mounting plate 292. Piston assembly 296 interfaces with an outer heat exchanger 302 of the cartridge assembly 124. Together, piston assembly 276 and piston assembly 296 cooperate to place pressure on cartridge assembly 124. In one embodiment, piston assembly 296 is eliminated, wherein only piston assembly 276 places pressure on cartridge assembly 124 that is counteracted by mounting plate 292.
  • piston assembly 276 and piston assembly 296 are similarly structured. As illustrated in more detail in FIG. 4, piston assembly 276 includes an outer piston plate 278 and an inner piston plate 280. Inner piston plate 280 includes an air pressure inlet 310 and airway channels 312. Inner piston plate 280 includes a gasket 314 that interfaces with the outer piston plate 278 (e.g., an inner ring thereof). During operation, air pressure is provided to inlet 310 and travels through airway channels 312. This increased air pressure causes movement of inner piston plate 280 away from outer piston plate 278. In turn, pressure is applied to the cartridge assembly 124, delivering a desired force to maintain contact among heat exchangers within the cartridge assembly 124. In one embodiment, an actuator (e.g., an air compressor) is configured to provide pressure to the piston assembly 276 and/or piston assembly 296. This pressure assists in maintaining contact among the heat exchangers of the cartridge assembly 124.
  • an actuator e.g., an air compressor
  • cartridge assembly 124 extends from a first end defined by outer heat exchanger 282 to a second end defined by outer heat exchanger 302.
  • Cartridge assembly 124 includes a plurality of fasteners 320 (e.g., including rods and nuts) that pass through each of the plurality of heat exchangers 262 and 264 and secured at outer heat exchanger 282 and outer heat exchanger 302. Planar surfaces of the plurality of heat exchangers 262 and 264 are positioned to face either the first end or the second end of the cartridge assembly 124.
  • cartridge assembly 124 is positioned between piston assembly 276 and piston assembly 296 such that the piston assemblies 276 and 296 can place compressive forces upon the cartridge assembly 124.
  • fluid is carried from one heat transfer source (i.e., heat source 108 or cold source 114) to first side ingress manifold 258A.
  • the first side ingress manifold 258A is fluidly coupled with each first side heat exchanger 264 (e.g., through a plurality of fluid conduits such as hoses).
  • First side fluid is sent through the plurality of first side heat exchangers 264 and into the first side egress manifold 258B (e.g., through a plurality of fluid conduits such as hoses).
  • first side egress manifold 258B is fluidly coupled with a pump (e.g., pump 110) that sends fluid from first side egress manifold 258B to one heat transfer source and back to first side ingress manifold 258 A.
  • pump 110 e.g., pump 110
  • fluid is carried from the other heat transfer source (i.e., heat source 108 or cold source 114) to second side ingress manifold 260A.
  • the second side ingress manifold 260A is, in turn, fluidly coupled with each second side heat exchangers 266 (e.g., through a plurality of fluid conduits such as hoses). Fluid is sent through the plurality of second side heat exchangers 266 and into the cold side egress manifold 260B (e.g., through a plurality of fluid conduits such as hoses).
  • second side egress manifold 260B is fluidly coupled with a pump (e.g., pump) 116 that sends fluid from second side egress manifold 260B to one heat transfer source and back to second side ingress manifold 260A.
  • pump e.g., pump
  • FIG. 9 illustrates a side view of a portion of cartridge assembly 124, including two first side heat exchangers 262A and 262B and a second side heat exchanger 264 positioned between the two first side heat exchangers 262A and 262B.
  • First side heat exchanger 262A includes a first, major planar surface 350 and a second, major planar surface 352 opposite the first planar surface 350.
  • second side heat exchanger 264 includes a first, major planar surface 354 and a second, major planar surface 356 defined by one or more cover plates opposite the first planar surface 354.
  • First side heat exchanger 262B also include a first, major planar surface 358 and a second, major planar surface 360 opposite the first planar surface 358.
  • Thermoelectric module assemblies 266 and power modules 268 are positioned between first side heat exchanger 262A and second side heat exchanger 264. Additionally, thermoelectric module assemblies 266 and power modules 268 are positioned between first side heat exchanger 262B and second side heat exchanger 264.
  • FIG. 10 illustrates a view of planar surface 350 of first side heat exchanger 262A.
  • thermoelectric module assemblies 266 and power modules 268 are mounted to planar surface 350.
  • Thermoelectric module assemblies 266 are connected to cover plates 380 and 382 of first side heat exchanger 262A.
  • Power modules 268 are supported on heat exchanger 262A.
  • a plurality of connectors 390 deliver electricity generated by thermoelectric module assemblies 266 to the power modules 268.
  • Power modules 268 can deliver electricity to one or more loads as desired.
  • Thermoelectric module assemblies 266 and power modules 268 are mounted to heat exchanger 262B similarly.
  • thermoelectric module assemblies 266 and two power modules 268 mounted to heat exchanger 262A
  • any number of thermoelectric module assemblies 266 and any number of power modules 268 can be utilized to harvest energy from cartridge assembly 124 and deliver power from the power modules 268 to a desired load.
  • Each thermoelectric module assembly 266 is mounted to a printed circuit board 392 and includes a plurality of thermoelectric generation elements 394, as illustrated.
  • Each element 394 includes a hot side substrate, a cold side substrate, and semiconductor devices positioned therebetween. The semiconductor devices are connected to connectors 390 that carries electrons to a specified electrical load (e.g., through a power module 268).
  • Each thermoelectric generation element 394 can be of any size or shape, including a conventional 40 mm x 40 mm size. In some embodiments depending on the size and shape of the thermoelectric generation module used, thermoelectric module assembly 266 may not require a printed circuit board.
  • thermoelectric elements 394 in some embodiments, can be interconnected in series, in parallel, in a combination of series and parallel, or independently connected to a power module 268.
  • Power module 268 can operate and invert electricity using any combination of 12V DC, 24V DC, 48V DC, HOv alternating current (AC), 220v AC, 240v AC, and 480v AC in a single or split phase.
  • thermoelectric elements 394 are connected in parallel.
  • thermoelectric elements 394’ are connected in senes.
  • FIG. 12A illustrates a side view of second side heat exchanger 264 with cover plates removed, wherein other heat exchangers within cartridge assembly 124 are of similar construction.
  • Heat exchanger 264 defines a plate 400, with one side of plate 400 forms planar surface 354 and one or more cover plates defining planar surface 356.
  • plate 400 is formed of aluminum, although other materials can be used.
  • plate 400 can be formed of a block, and features can be machined into the block using one or more material removal techniques such as milling, drilling, and others.
  • a seal (not shown) can be positioned in channel 408 to provide a fluid tight seal between plate 400 and one or more covers that define planar surface 356.
  • heat exchanger 264 is formed of a unitary body, for example, using an injection molding, casting, or additive printing technique.
  • Plate 400 defines an internal fluid path 430 extending from a first end 432 to a second end 434.
  • fluid path 430 includes a substantially square cross section as best illustrated in FIG. 8. Other sectional shapes can also be used.
  • fluid path 430 can include one planar surface, two planar surfaces, three planar surfaces, or four planar surfaces.
  • fluid path 430 is circular in cross section without a planar surface in cross section.
  • First end 432 and second end 434 each include a connector to fluidly connect fluid path 430 to a manifold.
  • first end 432 can be connected to first side ingress manifold 258A, whereas second end 434 is connected to first side egress manifold 258B.
  • fluid path 430 is circuitous or serpentine shaped, including straight segments parallel to one another and carrying fluid in opposite directions (e.g., a first straight segment 436 and a second straight segment 438) and connected through U-shaped ends (e.g., a U-shaped end 440). Other structures for fluid path 430 can also be used.
  • Plate 400 further includes a plurality of apertures 450 configured to accommodate rods to secure heat exchanger 264 to cartridge assembly 124.
  • fluid path 430 carries fluid from first end 432 to second end 434.
  • first end 432’ and second end 434’ are positioned on opposite sides of plate 400’.
  • Fluid path 430’ is similarly constructed to fluid path 430, with a serpentine shape.
  • first end 432’ can be connected to ingress manifold 258A on and second end 434’ can be connected to egress manifold 260B on an opposite side of cartridge assembly 124.

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Abstract

A thermoelectric generator assembly includes a cartridge assembly and a power module. The thermoelectric generator assembly further includes a first ingress manifold, a second ingress manifold, a first egress manifold and a second egress manifold. The cartridge assembly includes a first plurality of heat exchangers fluidly coupled with the first ingress manifold and the first egress manifold and a second plurality of heat exchangers fluidly coupled with the second ingress manifold and the second egress manifold. Thermoelectric module assemblies are positioned between the first and second plurality of heat exchangers and electrically connected to the power module.

Description

THERMOELECTRIC GENERATOR
BACKGROUND
[0001] Current thermoelectric devices are made from thermoelectric materials that convert thermal energy into electricity. These devices have limited commercial applicability due to high costs and low conversion performance compared with other technologies that accomplish similar energy generation or refrigeration. Due to interest in curbing greenhouse gas emissions and optimizing energy extraction from waste heat, improvements in thermoelectric devices are desired.
SUMMARY
[0002] Concepts presented herein relate to a thermoelectric generator assembly that includes a cartridge assembly and a power module. The thermoelectric generator assembly further includes a first ingress manifold, a second ingress manifold, a first egress manifold and a second egress manifold. The cartridge assembly includes a first plurality of heat exchangers fluidly coupled with the first ingress manifold and the first egress manifold and a second plurality of heat exchangers fluidly coupled with the second ingress manifold and the second egress manifold. Thermoelectric module assemblies are positioned between the first and second plurality of heat exchangers and electrically connected to the power module.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] FIG. l is a schematic block diagram of a thermoelectric generation system.
[0004] FIG. 2 is a perspective view of a thermoelectric generation system.
[0005] FIG. 3 is a partially exploded perspective view of a support frame.
[0006] FIG. 4 is a partially exploded perspective view of a piston assembly.
[0007] FIG. 5 is a perspective view of a cartridge assembly.
[0008] FIG. 6A is a first side view of the cartridge assembly of FIG. 5. [0009] FIG. 6B is a second side view of the cartridge assembly of FIG. 5, opposite the first side view of FIG. 6A.
[0010] FIG. 7 is a top view of the cartridge assembly of FIG. 5.
[0011] FIG. 8 is a sectional view of the cartridge assembly of FIG. 5, taken along a plane that is orthogonal to a direction of fluid flow within the cartridge assembly.
[0012] FIG. 9 is a side view of a portion of the cartridge assembly of FIG. 5.
[0013] FIG. 10 is a front view of a portion of the cartridge assembly of FIG. 5.
[0014] FIG. 11 is a front view of an alternative embodiment of a thermoelectric module assembly.
[0015] FIG. 12A is a front view of a first embodiment of a heat exchanger.
[0016] FIG. 12B is a front view of a second embodiment of a heat exchanger.
DESCRIPTION
[0017] FIG. 1 is a schematic block diagram of a thermoelectric generation system 100. In one embodiment, thermoelectric generation system 100 is utilized to generate electricity at oil and gas production facilities. Heat from combustion within a boiler at a facility can be sent to thermoelectric generation system 100 for conversion to electricity. In this embodiment, thermoelectric generation system 100 can be coupled with a production facility that heats the gas to reduce emissions of gas into the atmosphere. In another embodiment, thermoelectric generation system 100 can be utilized to generate electricity at facilities having an abundance of waste heat. Thermoelectric generation system 100 includes a thermoelectric generator assembly 102, a first fluid side, herein a hot fluid side 104, and a second fluid side, herein a cold fluid side 106. Thermoelectric generator assembly 102 generates electricity from a difference in temperature between hot fluid side 104 and cold fluid side 106.
[0018] Hot fluid side 104 defines a loop that includes a first thermal heat transfer source, herein a heat source 108, such as a boiler that heats fluid (e.g., a gas or liquid) within the hot fluid side 104. Heat source 108, in one embodiment, heats fluid within the hot fluid side 104 to a temperature above 200 degrees Fahrenheit, above 400 degrees Fahrenheit, above 500 degrees Fahrenheit and/or including between 500 to 1,000 degrees Fahrenheit. In some embodiments, hot fluid side 104 includes a pump 110 and/or sink 112. Pump 110 carries fluid throughout hot fluid side 104, whereas sink 112 accepts fluid exiting hot fluid side 104. In other embodiments, pump 110 and/or sink 112 can be eliminated. In still further embodiments, multiple pumps 110 can be used.
[0019] In another embodiment, heat source 108 is generated from gas combusted using a boiler such as a low NOx (nitrous oxide) boiler to heat fluid operating above 100,000 British thermal units (BTU), above 250,000 BTUs, above 500,000 BTUs, above 1,000,000 BTUs, and/or including between 1,000,000 BTUs to 10,000,000 BTUs.
[0020] Cold fluid side 106 defines a loop that includes a second thermal heat transfer source, herein a cold source 114, such as a chiller that cools fluid (e.g., a liquid or a gas) within cold fluid side 106. In some embodiments, cold fluid side 106 includes a pump 116 and/or sink 118. Pump 116 (which may include one or more pumps) carries fluid throughout cold fluid side 104, whereas sink 118 accepts fluid exiting cold fluid side 106. In other embodiments, the cold fluid side 106 of the thermoelectric generation system 100 can include an ammonia-based fluid that can be activated using the heat returning from the hot side manifold. In other embodiments, pump 116 and/or sink 118 can be eliminated.
[0021] Hot fluid side 104 provides hot fluid to thermoelectric generator assembly 102 through a manifold assembly 120, whereas cold fluid side 106 provides cold fluid to thermoelectric generator assembly 102 through a manifold assembly 122. Fluid from both manifold assembly 120 and manifold assembly 122 is provided to cartridge assembly 124. As discussed in more detail below, cartridge assembly 124 includes one or more hot fluid paths, one or more cold fluid paths, and one or more thermoelectric module assemblies. The thermoelectric module assemblies are positioned adjacent to both a hot fluid path and a cold fluid path and generate electricity based on a difference in temperature between the hot fluid path and the cold fluid path.
[0022] Electricity from the thermoelectric module assemblies in the form of direct current (DC) can be sent to a power module (or multiple power modules) 126, which in some embodiments includes a controller, DC/DC and DC/AC inverters, battery, and/or other components. Thermoelectric generator assembly 102, in one embodiment, can generate above 2 kilowatts (kW) of electricity, above 5 kWs, above lOkWs, above 25kW, and/or including between 25 and lOOkW.
[0023] FIG. 2 is a perspective view of an example thermoelectric generator assembly 102. Thermoelectric generator assembly 102 includes a support frame 200 that supports cartridge assembly 124. Support frame 200 is further illustrated in FIG. 3 and includes side supports 254 and 256. Manifold assemblies 258 and 260 are positioned adjacent the frame 200 on either side and are fluidly coupled with the cartridge assembly 124 (e.g., through a plurality of hoses (not shown)). In another embodiment, manifold assemblies 258 and 260 can be supported directly by base 204. Manifold assembly 258 includes an ingress manifold 258 A and an egress manifold 258B. In addition, manifold assembly 260 includes an ingress manifold 260A and an egress manifold 260B.
[0024] In the embodiment illustrated, manifold assembly 258 carries fluid from one fluid side (e.g., hot fluid side 104), whereas manifold assembly 260 carries fluid from the other fluid side (e g., cold fluid side 106). In another embodiment, manifold assemblies 258 and 260 can carry fluid from both sides, for example manifold 258A can serve as an ingress manifold for a first side (e.g., hot fluid side 104), with manifold 260B serving as an egress manifold for the first side. In addition, manifold 260A can serve as an ingress manifold for a second side (e.g., cold fluid side 106), with manifold 258B serving as an egress manifold for the second side.
[0025] Cartridge assembly 124, further illustrated in FIGS. 5-8, supports a plurality of first side heat exchangers 262, a plurality of second side heat exchangers 264, a plurality of thermoelectric module assemblies 266 and a plurality of power modules 268 receiving electricity from the plurality of thermoelectric module assemblies 266. Each of the plurality of thermoelectric module assemblies 266 is positioned between a respective first side heat exchanger 262 and a respective second side heat exchanger 264. In the embodiment illustrated, cartridge assembly 124 includes twenty-nine heat exchangers, including fifteen first side heat exchangers 262 and fourteen second side heat exchangers 264. In other embodiments, cartridge assembly 124 can include at least five, at least ten, at least fifteen, at least twenty or more than thirty heat exchangers as desired.
[0026] FIG. 9 is a side view of an example assembly that includes two first side heat exchangers 262 and a second side heat exchanger 264 positioned between the two first side heat exchangers 262. Thermoelectric module assemblies 266 and power module assemblies 268 are positioned on either side of the second side heat exchanger 264.
[0027] With reference to FIG. 3, side support 254 includes a plurality of gusset plates or supports 270 supporting a mounting plate 272 and a piston assembly 276 connected to mounting plate 272. Piston assembly 276 interfaces with an outer heat exchanger 282 of the cartridge assembly 124. Similarly, side support 256 includes a plurality of gusset plates or supports 290 supporting a mounting plate 292 and a piston assembly 296 connected to mounting plate 292. Piston assembly 296 interfaces with an outer heat exchanger 302 of the cartridge assembly 124. Together, piston assembly 276 and piston assembly 296 cooperate to place pressure on cartridge assembly 124. In one embodiment, piston assembly 296 is eliminated, wherein only piston assembly 276 places pressure on cartridge assembly 124 that is counteracted by mounting plate 292.
[0028] In one embodiment, piston assembly 276 and piston assembly 296 are similarly structured. As illustrated in more detail in FIG. 4, piston assembly 276 includes an outer piston plate 278 and an inner piston plate 280. Inner piston plate 280 includes an air pressure inlet 310 and airway channels 312. Inner piston plate 280 includes a gasket 314 that interfaces with the outer piston plate 278 (e.g., an inner ring thereof). During operation, air pressure is provided to inlet 310 and travels through airway channels 312. This increased air pressure causes movement of inner piston plate 280 away from outer piston plate 278. In turn, pressure is applied to the cartridge assembly 124, delivering a desired force to maintain contact among heat exchangers within the cartridge assembly 124. In one embodiment, an actuator (e.g., an air compressor) is configured to provide pressure to the piston assembly 276 and/or piston assembly 296. This pressure assists in maintaining contact among the heat exchangers of the cartridge assembly 124.
[0029] In the illustrated embodiment, cartridge assembly 124 extends from a first end defined by outer heat exchanger 282 to a second end defined by outer heat exchanger 302. Cartridge assembly 124 includes a plurality of fasteners 320 (e.g., including rods and nuts) that pass through each of the plurality of heat exchangers 262 and 264 and secured at outer heat exchanger 282 and outer heat exchanger 302. Planar surfaces of the plurality of heat exchangers 262 and 264 are positioned to face either the first end or the second end of the cartridge assembly 124. Upon assembly, cartridge assembly 124 is positioned between piston assembly 276 and piston assembly 296 such that the piston assemblies 276 and 296 can place compressive forces upon the cartridge assembly 124.
[0030] During operation, fluid is carried from one heat transfer source (i.e., heat source 108 or cold source 114) to first side ingress manifold 258A. The first side ingress manifold 258A is fluidly coupled with each first side heat exchanger 264 (e.g., through a plurality of fluid conduits such as hoses). First side fluid is sent through the plurality of first side heat exchangers 264 and into the first side egress manifold 258B (e.g., through a plurality of fluid conduits such as hoses). In one embodiment, in a closed-loop first side, first side egress manifold 258B is fluidly coupled with a pump (e.g., pump 110) that sends fluid from first side egress manifold 258B to one heat transfer source and back to first side ingress manifold 258 A.
[0031] Similarly, fluid is carried from the other heat transfer source (i.e., heat source 108 or cold source 114) to second side ingress manifold 260A. The second side ingress manifold 260A is, in turn, fluidly coupled with each second side heat exchangers 266 (e.g., through a plurality of fluid conduits such as hoses). Fluid is sent through the plurality of second side heat exchangers 266 and into the cold side egress manifold 260B (e.g., through a plurality of fluid conduits such as hoses). In one embodiment, in a closed-loop second side, second side egress manifold 260B is fluidly coupled with a pump (e.g., pump) 116 that sends fluid from second side egress manifold 260B to one heat transfer source and back to second side ingress manifold 260A.
[0032] FIG. 9 illustrates a side view of a portion of cartridge assembly 124, including two first side heat exchangers 262A and 262B and a second side heat exchanger 264 positioned between the two first side heat exchangers 262A and 262B. First side heat exchanger 262A includes a first, major planar surface 350 and a second, major planar surface 352 opposite the first planar surface 350. In a similar manner, second side heat exchanger 264 includes a first, major planar surface 354 and a second, major planar surface 356 defined by one or more cover plates opposite the first planar surface 354. First side heat exchanger 262B also include a first, major planar surface 358 and a second, major planar surface 360 opposite the first planar surface 358. Thermoelectric module assemblies 266 and power modules 268 are positioned between first side heat exchanger 262A and second side heat exchanger 264. Additionally, thermoelectric module assemblies 266 and power modules 268 are positioned between first side heat exchanger 262B and second side heat exchanger 264.
[0033] FIG. 10 illustrates a view of planar surface 350 of first side heat exchanger 262A. As illustrated, thermoelectric module assemblies 266 and power modules 268 are mounted to planar surface 350. Thermoelectric module assemblies 266 are connected to cover plates 380 and 382 of first side heat exchanger 262A. Power modules 268 are supported on heat exchanger 262A. A plurality of connectors 390 deliver electricity generated by thermoelectric module assemblies 266 to the power modules 268. Power modules 268 can deliver electricity to one or more loads as desired. Thermoelectric module assemblies 266 and power modules 268 are mounted to heat exchanger 262B similarly. Although illustrated with twelve thermoelectric module assemblies 266 and two power modules 268 mounted to heat exchanger 262A, any number of thermoelectric module assemblies 266 and any number of power modules 268 can be utilized to harvest energy from cartridge assembly 124 and deliver power from the power modules 268 to a desired load.
[0034] Each thermoelectric module assembly 266 is mounted to a printed circuit board 392 and includes a plurality of thermoelectric generation elements 394, as illustrated. Each element 394 includes a hot side substrate, a cold side substrate, and semiconductor devices positioned therebetween. The semiconductor devices are connected to connectors 390 that carries electrons to a specified electrical load (e.g., through a power module 268). Each thermoelectric generation element 394 can be of any size or shape, including a conventional 40 mm x 40 mm size. In some embodiments depending on the size and shape of the thermoelectric generation module used, thermoelectric module assembly 266 may not require a printed circuit board.
[0035] Each of the thermoelectric elements 394, in some embodiments, can be interconnected in series, in parallel, in a combination of series and parallel, or independently connected to a power module 268. Power module 268 can operate and invert electricity using any combination of 12V DC, 24V DC, 48V DC, HOv alternating current (AC), 220v AC, 240v AC, and 480v AC in a single or split phase. In the embodiment of FIG. 10, thermoelectric elements 394 are connected in parallel. Alternatively, as illustrated in FIG. 11, thermoelectric elements 394’ are connected in senes. [0036] FIG. 12A illustrates a side view of second side heat exchanger 264 with cover plates removed, wherein other heat exchangers within cartridge assembly 124 are of similar construction. Heat exchanger 264 defines a plate 400, with one side of plate 400 forms planar surface 354 and one or more cover plates defining planar surface 356. In one embodiment, plate 400 is formed of aluminum, although other materials can be used. For example, plate 400 can be formed of a block, and features can be machined into the block using one or more material removal techniques such as milling, drilling, and others. In addition, a seal (not shown) can be positioned in channel 408 to provide a fluid tight seal between plate 400 and one or more covers that define planar surface 356. In an alternative embodiment, heat exchanger 264 is formed of a unitary body, for example, using an injection molding, casting, or additive printing technique.
[0037] Plate 400 defines an internal fluid path 430 extending from a first end 432 to a second end 434. In the embodiment illustrated, fluid path 430 includes a substantially square cross section as best illustrated in FIG. 8. Other sectional shapes can also be used. For example, fluid path 430 can include one planar surface, two planar surfaces, three planar surfaces, or four planar surfaces. In other embodiments, fluid path 430 is circular in cross section without a planar surface in cross section. First end 432 and second end 434 each include a connector to fluidly connect fluid path 430 to a manifold. For example, first end 432 can be connected to first side ingress manifold 258A, whereas second end 434 is connected to first side egress manifold 258B. In the embodiment illustrated, fluid path 430 is circuitous or serpentine shaped, including straight segments parallel to one another and carrying fluid in opposite directions (e.g., a first straight segment 436 and a second straight segment 438) and connected through U-shaped ends (e.g., a U-shaped end 440). Other structures for fluid path 430 can also be used. Plate 400 further includes a plurality of apertures 450 configured to accommodate rods to secure heat exchanger 264 to cartridge assembly 124. During use, fluid path 430 carries fluid from first end 432 to second end 434.
[0038] In an alternative embodiment of a heat exchanger 264’ illustrated in FIG. 12B, first end 432’ and second end 434’ are positioned on opposite sides of plate 400’. Fluid path 430’ is similarly constructed to fluid path 430, with a serpentine shape. In one example embodiment, first end 432’ can be connected to ingress manifold 258A on and second end 434’ can be connected to egress manifold 260B on an opposite side of cartridge assembly 124. [0039] Various embodiments of the invention have been described above for purposes of illustrating the details thereof and to enable one of ordinary skill in the art to make and use the invention. The details and features of the disclosed embodiment[s] are not intended to be limiting, as many variations and modifications will be readily apparent to those of skill in the art. Accordingly, the scope of the present disclosure is intended to be interpreted broadly and to include all variations and modifications coming within the scope and spirit of the appended claims and their legal equivalents.

Claims

1. A thermoelectric generator assembly, comprising: a cartridge assembly defining a first end and a second end opposite the first end, comprising: a first plurality of heat exchangers, each of the first plurality of heat exchangers defining a first major planar surface, a second major planar surface opposite the first planar surface, and a fluid path positioned between the first planar surface and the second planar surface, wherein the first plurality of heat exchangers includes a first outer heat exchanger having its first major planar surface facing the first end of the cartridge assembly and a second outer heat exchanger having its second major planar surface facing the second end of the cartridge assembly; a second plurality of heat exchangers, each of the second plurality of heat exchangers defining a first major planar surface, a second major planar surface opposite the first planar surface, and a fluid path positioned between the first planar surface and the second planar surface; a first plurality of thermoelectric module assemblies, each of the first plurality of thermoelectric module assemblies positioned to contact the second major planar surface of one of the first plurality of heat exchangers and the first major planar surface of one of the second plurality of heat exchangers; and a second plurality of thermoelectric module assemblies, each of the second plurality of thermoelectric module assemblies positioned to contact the first major planar surface of one of the first plurality of heat exchangers and the second major planar surface of one of the second plurality of heat exchangers; a first ingress manifold fluidly coupled with each fluid path of the first plurality of heat exchangers; a first egress manifold fluidly coupled with each fluid path of the first plurality of heat exchangers; a second ingress manifold fluidly coupled with each fluid path of the second plurality of heat exchangers; a second egress manifold fluidly coupled with each fluid path of the second plurality of heat exchangers; and a power module electrically connected to each of the first plurality of thermoelectric module assemblies and each of the second plurality of thermoelectric module assemblies.
2. The thermoelectric generator assembly of claim 1, wherein the cartridge assembly includes a piston assembly, wherein an actuator is configured to apply pressure to the piston assembly to maintain pressure throughout the cartridge assembly.
3. The thermoelectric generator assembly of claim 1, wherein the first ingress manifold and the second egress manifold are positioned on a first side of the cartridge assembly and the first egress manifold and the second ingress manifold are positioned on a second side of the cartridge assembly, opposite the first side.
4. The thermoelectric generator assembly of claim 1, wherein a number of the first plurality of heat exchangers is at least five.
5. The thermoelectric generator assembly of claim 1, wherein each fluid path of the first plurality of heat exchangers and the second plurality of heat exchangers includes a serpentine path.
6. The thermoelectric generator assembly of claim 1, wherein each fluid path of the first plurality of heat exchangers and the second plurality of heat exchangers includes a planar surface.
7. The thermoelectric generator assembly of claim 1, wherein each fluid path of the first plurality of heat exchangers and the second plurality of heat exchangers defines a square cross section.
8. A cartridge assembly having a first end and a second end opposite the first end, the cartridge assembly configured for use in a thermoelectric generator system having a first ingress manifold, a first egress manifold, a second ingress manifold and a second egress manifold, the cartridge assembly comprising: a first plurality of heat exchangers, each heat exchanger of the first plurality of heat exchangers defining a first planar surface, a second planar surface, and an internal serpentine fluid path positioned between the first planar surface and the second planar surface, the fluid path configured to be fluidly coupled with the first ingress manifold and the first egress manifold, wherein the first plurality of heat exchangers includes a first outer heat exchanger having its first major planar surface facing the first end of the cartridge assembly and a second outer heat exchanger having its second major planar surface facing the second end of the cartridge assembly; a second plurality of heat exchangers, each of the second plurality of heat exchangers defining a first major planar surface, a second major planar surface opposite the first planar surface, and an internal serpentine fluid path positioned between the first planar surface and the second planar surface, the fluid path configured to be coupled to the second ingress manifold and the second egress manifold; a first plurality of thermoelectric module assemblies, each of the first plurality of thermoelectric module assemblies positioned to contact the second major planar surface of one of the first plurality of heat exchangers and the first major planar surface of one of the second plurality of heat exchangers; and a second plurality of thermoelectric module assemblies, each of the second plurality of thermoelectric module assemblies positioned to contact the first major planar surface of one of the first plurality of heat exchangers and the second major planar surface of one of the second plurality of heat exchangers.
9. The cartridge assembly of claim 8, further comprising a first end plate and a second end plate opposite the first end plate, wherein a plurality of support rods connect the first end plate and the second end plate.
10. The cartridge assembly of claim 9, wherein each heat exchanger of the first plurality of heat exchangers and each heat exchanger of the second plurality of heat exchangers include apertures to accommodate the plurality of support rods.
11. The cartridge assembly of claim 8, further comprising a piston assembly, wherein an actuator is configured to apply pressure to the piston assembly to maintain pressure throughout the cartridge assembly.
12. The cartridge assembly of claim 8, wherein a number of the first plurality of heat exchangers is at least five.
13. The cartridge assembly of claim 8, wherein each fluid path of the first plurality of heat exchangers and the second plurality of heat exchangers includes a planar surface.
14. The cartridge assembly of claim 8, wherein each fluid path of the first plurality of heat exchangers and the second plurality of heat exchangers defines a square cross section.
15. A thermoelectric generation system, comprising: a first heat transfer source; a first ingress manifold thermally coupled with the first heat transfer source; a second heat transfer source; a second ingress manifold thermally coupled with the second heat transfer source; a cartridge assembly defining a first end and a second end opposite the first end, comprising: a first plurality of heat exchangers fluidly coupled with the first ingress manifold, each of the first plurality of heat exchangers defining a first major planar surface, a second major planar surface opposite the first planar surface, and a fluid path positioned between the first planar surface and the second planar surface, wherein the first plurality of heat exchangers includes a first outer heat exchanger having its first major planar surface facing the first end of the cartridge assembly and a second outer heat exchanger having its second major planar surface facing the second end of the cartridge assembly; a second plurality of heat exchangers fluidly coupled with the second ingress manifold, each of the second plurality of heat exchangers defining a first major planar surface, a second major planar surface opposite the first planar surface, and a fluid path positioned between the first planar surface and the second planar surface; a first plurality of thermoelectric module assemblies, each of the first plurality of thermoelectric module assemblies positioned to contact the second major planar surface of one of the first plurality of heat exchangers and the first major planar surface of one of the second plurality of heat exchangers; and a second plurality of thermoelectric module assemblies, each of the second plurality of thermoelectric module assemblies positioned to contact the first major planar surface of one of the first plurality of heat exchangers and the second major planar surface of one of the second plurality of heat exchangers; a first egress manifold fluidly coupled with each fluid path of the first plurality of heat exchangers; a second egress manifold fluidly coupled with each fluid path of the second plurality of heat exchangers; and a power module electrically connected to each of the first plurality of thermoelectric module assemblies and each of the second plurality of thermoelectric module assemblies.
16. The thermoelectric generation system of claim 15, wherein the first heat transfer source is a boiler.
17. The thermoelectric generation system of claim 15, wherein the first heat transfer source is a chiller.
18. The thermoelectric generation system of claim 15, wherein a number of the first plurality of heat exchangers is at least five.
19. The thermoelectric generation system of claim 15, further comprising a pump fluidly coupled with the first egress manifold, the pump configured to transfer fluid to the first heat transfer source and to the first ingress manifold.
20. The thermoelectric generation system of claim 15, further comprising a pump fluidly coupled with the second egress manifold, the pump configured to transfer fluid to the second heat transfer source and to the second ingress manifold.
PCT/US2024/013897 2023-01-31 2024-01-31 Thermoelectric generator Ceased WO2024163685A1 (en)

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US20120102933A1 (en) * 2010-10-27 2012-05-03 Basf Se Thermoelectric generator
WO2017100718A1 (en) * 2015-12-10 2017-06-15 Alphabet Energy, Inc. Multi-layer thermoelectric generator
US20180261749A1 (en) * 2014-12-16 2018-09-13 Titanx Holding Ab Energy recovering assembly and a method of providing the same
CN207896888U (en) * 2018-02-28 2018-09-21 北京科技大学 A kind of close-coupled temperature difference electricity generation device
US20200328337A1 (en) * 2016-05-25 2020-10-15 Yanmar Co., Ltd. Thermoelectric power generation device and thermoelectric power generation system

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20120102933A1 (en) * 2010-10-27 2012-05-03 Basf Se Thermoelectric generator
US20180261749A1 (en) * 2014-12-16 2018-09-13 Titanx Holding Ab Energy recovering assembly and a method of providing the same
WO2017100718A1 (en) * 2015-12-10 2017-06-15 Alphabet Energy, Inc. Multi-layer thermoelectric generator
US20200328337A1 (en) * 2016-05-25 2020-10-15 Yanmar Co., Ltd. Thermoelectric power generation device and thermoelectric power generation system
CN207896888U (en) * 2018-02-28 2018-09-21 北京科技大学 A kind of close-coupled temperature difference electricity generation device

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