Thin-Film Thermoelectric Module for Power Generator Applications Using a Screen-Printing Method

A new process for fabricating a low-cost thermoelectric module using a screen-printing method has been developed. Thermoelectric properties of screen-printed ZnSb films were investigated in an effort to develop a thermoelectric module with low cost per watt. The screen-printed Zn _x Sb_1−x films showed a low carrier concentration and high Seebeck coefficient when x was in the range of 0.5 to 0.57 and the annealing temperature was kept below 550°C. When the annealing temperature was higher than 550°C, the carrier concentration of the Zn _x Sb_1−x films reached that of a metal, leading to a decrease of the Seebeck coefficient. In the present experiment, the optimized carrier concentration of screen-printed ZnSb was 7 × 10¹⁸/cm³. The output voltage and power density of the ZnSb film were 10 mV and 0.17 mW/cm², respectively, at ΔT = 50 K. A thermoelectric module was produced using the proposed screen-printing approach with ZnSb and CoSb₃ as p-type and n-type thermoelectric materials, respectively, and copper as the pad metal.     

Individual Module Maximum Power Point Tracking for Thermoelectric Generator Systems

In a thermoelectric generator (TEG) system the DC/DC converter is under the control of a maximum power point tracker which ensures that the TEG system outputs the maximum possible power to the load. However, if the conditions, e.g., temperature, health, etc., of the TEG modules are different, each TEG module will not produce its maximum power. If each TEG module is controlled individually, each TEG module can be operated at its maximum power point and the TEG system output power will therefore be higher. In this work a power converter based on noninverting buck–boost converters capable of handling four TEG modules is presented. It is shown that, when each module in the TEG system is operated under individual maximum power point tracking, the system output power for this specific application can be increased by up to 8.4% relative to the situation when the modules are connected in series and 16.7% relative to the situation when the modules are connected in parallel.     

Aircraft-Specific Thermoelectric Generator Module

Autonomous sensor nodes for wireless sensor networks are currently under discussion for aircraft structural health monitoring. Self-sufficient operation of a sensor node requires a positive power budget for sensing, processing, and communication tasks. Energy harvesting for autonomous powering by thermoelectric devices depends strongly on maintaining the temperature difference within the aircraft operation envelope. Aircraft pass through huge outside temperature variations and, in addition, provide heated cabin environments. To make use of these temperature differences most efficiently, additional effort for heat conduction and installation is required to maintain the temperature gradient. However, to keep the complexity of system implementation as low as possible we report in this paper on an aircraft-specific thermoelectric generator module which consists of a phase-change material attached to the thermoelectric generator at one side. If this module is exposed to the environmental conditions of an aircraft envelope, the phase transition and heat capacity of the attached material lead to unbalanced temperature levels on the two sides of the generator. Simulations with realistic aircraft parameters have been done and first tests of the breadboard in a climate chamber have shown promising results.     

A General Model for the Electric Power and Energy Efficiency of a Solar Thermoelectric Generator

A general model for the electric power and energy efficiency of a solar thermoelectric generator is discussed, considering the influences of the input energy, the thermal conductivity, the absorptivity and emissivity of the heat collector, and the cooling water. The influences of these factors on the performance of the thermoelectric device are discussed, considering the thermoelectric generator as a whole, including the heat collector, the thermoelectric device, and the cooling. Results show that high input energy, and high absorptivity and low emissivity of the heat collector, are helpful for obtaining a high-performance thermoelectric generator. A high thermal transfer coefficient of the cooling water can increase the temperature difference across the thermoelectric device but results in greater accessory power requirements if increased further.     

Prototype Combined Heater/Thermoelectric Power Generator for Remote Applications

This study presents a prototype thermoelectric generator (TEG) developed for remote applications in villages that are not connected to the electrical power grid. For ecological and economic reasons, there is growing interest in harvesting waste heat from biomass stoves to produce some electricity. Because regular maintenance is not required, TEGs are an attractive choice for small-scale power generation in inaccessible areas. The prototype developed in our laboratory is especially designed to be implemented in stoves that are also used for domestic hot water heating. The aim of this system is to provide a few watts to householders, so they have the ability to charge cellular phones and radios, and to get some light at night. A complete prototype TEG using commercial (bismuth telluride) thermoelectric modules has been built, including system integration with an electric DC/DC converter. The DC/DC converter has a maximum power point tracker (MPPT) driven by an MC9SO8 microcontroller, which optimizes the electrical energy stored in a valve-regulated lead–acid battery. Physical models were used to study the behavior of the thermoelectric system and to optimize the performance of the MPPT. Experiments using a hot gas generator to simulate the exhaust of the combustion chamber of a stove are used to evaluate the system. Additionally, potential uses of such generators are presented.     

Power Conditioner with Variable Switching Control for Thermoelectric Generator Systems

A thermoelectric (TE) power conditioner maintaining high efficiency over a wide input power range has been developed. Variable switching frequency operation is shown to give an improvement in efficient operating range. The input range showing more than 90% conversion efficiency is expanded to more than 25% by introducing a low-power controller circuit and variable switching frequency control. The TE power conditioner showed excellent response against a change in thermoelectric generator (TEG) output and load, making it suitable for automotive applications.     

Thermoelectric Generator for a Stationary Diesel Plant

This paper describes the development and testing of a thermoelectric generator (TEG) using the exhaust heat of a 50-kW stationary diesel power plant. The generator consists of six units that represent primary generators for each diesel engine cylinder. Each primary generator comprises five sections with gas heat exchangers, thermoelectric modules, and liquid heat exchangers. The sections were optimized for the exhaust gas operating temperatures. The generator electric power was 2.1 kW at rated power of 2.2 kW, corresponding to 4.4% of the diesel plant electric power.     

Multi-parameter Optimization of a Thermoelectric Power Generator and Its Working Conditions

The global optimal working conditions and optimal couple design for thermoelectric (TE) generators with realistic thermal coupling between the heat reservoirs and the TE couple were studied in the current work. The heat fluxes enforced by the heat reservoirs at the hot and the cold junctions of the TE couple were used in combination with parameter normalization to obtain a single cubic algebraic equation relating the temperature differences between the TE couple junctions and between the heat reservoirs, through the electric load resistance ratio, the reservoir thermal conductance ratio, the reservoir thermal conductance to the TE couple thermal conductance ratio, the Thomson to Seebeck coefficient ratio, and the figure of merit (Z) of the material based on the linear TE transport equations and their solutions. A broad reservoir thermal conductance ranging between 0.01  W/K and 100 W/K and TE element length ranging from 10^-7 m to 10^-3 m were explored to find the global optimal systems. The global optimal parameters related to the working conditions, i.e., reservoir thermal conductance ratio and electric load resistance ratio, and the optimal design parameter related to the TE couple were determined for a given TE material. These results demonstrated that the internal and external electric resistance, the thermal resistance between the reservoirs, the thermal resistance between the reservoir and the TE couple, and the optimal thermoelement length have to be well coordinated to obtain optimal power production.     

Modeling the Building Blocks of a 10% Efficient Segmented Thermoelectric Power Generator

This paper describes the development of a modeling tool used for design and analysis of the building blocks of thermoelectric generators (TEGs). The described model captures the performance of a thermoelectric couple at varying loads and temperatures. The model includes the effects of interfacial resistances and other thermal losses. Validation experiments have been conducted, and the results are discussed. Once validated, the model was then used to design a 10% efficient segmented TEG, which was then built and tested. With this effective design tool along with improving thermoelectric material performance, a 14% efficient TEG is within reach.     

Development of a Thermal Buffering Device to Cope with Temperature Fluctuations for a Thermoelectric Power Generator

To stabilize the heat input to a thermoelectric generator (TEG) and protect it from large temperature fluctuations, a thermal buffering device (TBD) was fabricated and examined using a typical Bi-Te TEG module and a brand-new Mg₂Si TEG module. The TBD comprises two adjoining heat storage containers, each containing different alloys, which can be optimized for the temperature range of the TEG. The combination of two alloys in series diminishes the thermal fluctuations, stabilizing the heat input to the TEG module. This is achieved by having two metallic materials with large enthalpies of fusion that can be placed between the heat source and the TEG. The combination of the two alloys can be optimized for the temperature ranges of Bi-Te, Pb-Te, or Co-Sb. For the Bi-Te TEG, 15Al-85Zn and 30Sn-70Zn alloys were used for the heat source side and the TEG side, respectively. The corresponding alloys for the Mg₂Si TEG were 20Ni-80Al and 7Si-93Al. With the use of a TBD, the Bi-Te TEG exhibited no notable damage even in the rather high temperature range beyond ??573?K. For the Mg₂Si TEG, no operational damage of the Mg₂Si TEG module was observed even with a temperature of 1020?K.     

Waste Heat Recovery from a Marine Waste IncineratorUsing a Thermoelectric Generator

A marine waste incinerator has been evaluated for waste heat harvesting using thermoelectric generators (TEG). The application has been evaluated using mathematical modeling to optimize the heat exchanger and some vital design parameters of the TEG. The calculation shows that it is possible to extract 58?kW_el at a price of 6.6?US$/W from an 850-kW_th incinerator when optimizing for maximum power. However, minimizing the cost, it is possible to get 25?kW_el at a price of 2.5?US$/W. A trade-off between the two targets leads to a combination that gives 38?kW_el at a price of 2.7?US$/W.     

Reliable Thermoelectric Module Design under Opposing Requirements from Structural and Thermoelectric Considerations

Structural reliability of thermoelectric generation (TEG) systems still remains an issue, especially for applications such as large-scale industrial or automobile exhaust heat recovery, in which TEG systems are subject to dynamic loads and thermal cycling. Traditional thermoelectric (TE) system design and optimization techniques, focused on performance alone, could result in designs that may fail during operation as the geometric requirements for optimal performance (especially the power) are often in conflict with the requirements for mechanical reliability. This study focused on reducing the thermomechanical stresses in a TEG system without compromising the optimized system performance. Finite element simulations were carried out to study the effect of TE element (leg) geometry such as leg length and cross-sectional shape under constrained material volume requirements. Results indicated that the element length has a major influence on the element stresses whereas regular cross-sectional shapes have minor influence. The impact of TE element stresses on the mechanical reliability is evaluated using brittle material failure theory based on Weibull analysis. An alternate couple configuration that relies on the industry practice of redundant element design is investigated. Results showed that the alternate configuration considerably reduced the TE element and metallization stresses, thereby enhancing the structural reliability, with little trade-off in the optimized performance. The proposed alternate configuration could serve as a potential design modification for improving the reliability of systems optimized for thermoelectric performance.     

Self-Contained Thermoelectric Generator for Cell Phones

Results of research and development of a 1 W thermoelectric generator for cell phones are presented. A physical model of the generator with catalytic combustion of gas fuel is proposed. A computer simulation method is used to determine the optimal parameters of the thermopile, catalytic heat source, and microgenerator heat rejection system whereby the efficiency of gas combustion heat conversion into electrical energy is a factor of two higher compared with existing analogs. The generator design is described, and results of experimental research on its parameters and the charging rate of cell phone batteries with capacity of 900 mA h to 1600 mA h are given. In the self-contained operating mode of various low-power devices, the elaborated thermoelectric generator with a catalytic heat source is an alternative to traditional sources of chemical energy.     

Power Generation Characteristics of Mg2Si Uni-Leg Thermoelectric Generator

Mg₂Si thermoelectric (TE) elements were fabricated by a plasma-activated sintering method using a commercial polycrystalline n-type Mg₂Si source produced by the Union Material Co., Ltd. This material typically has a ZT value of ??0.6. A monobloc plasma-activated sintering technique was used to form Ni electrodes on the TE elements. The dimensions of a single element were 4.0?mm?×?4.0?mm?×?10?mm, and these were used to construct a TE module comprising nine elements connected in series. To reduce the electrical and thermal contact resistance of the module, each part of the module, i.e., the elements, terminals, and insulating plates, was joined using a Ag-based brazing alloy. In addition, to maintain the temperature difference between the top and bottom of the module, a thermal insulation board was installed in it. The observed values of open-circuit voltage (V _OC) and output power (P) of a uni-leg structure module were 594?mV and 543?mW, respectively, at a maximum ??T?=?500?K.     

Solar Thermoelectric Generator for Micropower Applications

Solar thermoelectric generators (STG) using cheap parabolic concentrators with high-ZT modules can be a cost-effective alternative to solar photovoltaics for micropower generation. A thermodynamic analysis is presented for predicting the thermal-to-electrical conversion efficiency for the generator. With solar concentration of 66× suns, a system efficiency of 3% was measured for a commercial Bi₂Te₃ module with output power of 1.8 W. Using novel thermoelectric materials such as n-type ErAs:(InGaAs)_1−x (InAlAs) _x and p-type (AgSbTe) _x (PbSnTe)_1−x , a conversion efficiency of 5.6% can be achieved for a STG at 120× suns.     

Design of a Thin-Film Thermoelectric Generator for Low-Power Applications

Russian Microelectronics - The results of designing a thermoelectric generator (TEG) for low-power applications, such as human monitoring systems, are presented. The generator principle is based on...     

Examination of a Thermally Viable Structure for an Unconventional Uni-Leg Mg2Si Thermoelectric Power Generator

We have fabricated an unconventional uni-leg structure thermoelectric generator (TEG) element using quad thermoelectric (TE) chips of Sb-doped n-Mg₂Si, which were prepared by a plasma-activated sintering process. The power curve characteristics, the effect of aging up to 500?h, and the thermal gradients at several points on the module were investigated. The observed maximum output power with the heat source at 975?K and the heat sink at 345?K was 341?mW, from which the ??T for the TE chip was calculated to be about 333?K. In aging testing in air ambient, a remarkable feature of the results was that there was no notable change from the initial resistance of the TEG module for as long as 500?h. The thermal distribution for the fabricated uni-leg TEG element was analyzed by finite-element modeling using ANSYS software. To tune the calculation parameters of ANSYS, such as the thermal conductance properties of the corresponding coupled materials in the module, precise measurements of the temperature at various probe points on the module were made. Then, meticulous verification between the measured temperature values and the results calculated by ANSYS was carried out to optimize the parameters.