Same plane multiple thermoelectric mounting system

• US 8,227,682 B2
• Filed: 04/13/2004
• Issued: 07/24/2012
• Est. Priority Date: 04/17/2003
• Status: Active Grant

• Current Assignee: Steven Bauman
• Original Assignee: Watts Thermoelectric, LLC
• Inventors: Watts, Phillip C.
• Primary Examiner(s): Michener, Jennifer
• Assistant Examiner(s): Mowla, Golam
• Application Number:
  US10/823,353
• Publication Number:
  US 20040206386A1
• Time in Patent Office: 3,024 Days
• Field of Search: 123/263, 165/254, 165/104.33, 136/203, 136/205, 62/32, 62/33, 622/592
• US Class Current: 136/205
• CPC Class Codes: H10N 10/13 characterised by the heat-exchanging means at the junction

Abstract

This invention is intended to provide a mechanical building block system independent of mechanical tolerances of generator stack elements consisting of multiple parallel in plane elements that can be mass produced and mass assembled without sorting or lapping or machining in place. This implementation allows for simple maintenance of interchangeable unmatched parts.

Claims

1. A thermoelectric generator for generating electricity from a temperature differential between a first fluid and a second fluid, the thermoelectric generator comprising:

a plurality of thermoelectric modules, wherein;

each of the thermoelectric modules comprises a first side and a second side; and

each of the thermoelectric modules generates electricity when there is a difference in temperature between the first side and the second side;

a first thermal module, wherein;

the first thermal module comprises a first block including a first passage through the first fluid flows through the first block; and

the first thermal module is configured to exchange heat with the first sides of at least two of the plurality of thermoelectric modules; and

a plurality of second thermal modules, wherein;

each of the plurality of second thermal modules comprises a respective second block including a respective second passage through which the second fluid flows through the respective second block; and

a side of each of the second thermal modules is configured to exchange heat with exactly one of the thermoelectric modules through the second side of the respective thermoelectric module;

at least two of the plurality of second thermal modules reside on one side of the first thermal module, both of their respective thermoelectric modules being in contact with one planar face of the first thermal module;

the two second thermal modules that are on one side of the first thermal module are flexibly coupled to each other; and

each of the second thermal modules accommodates all axis mechanical variance in its respective thermoelectric module.

2. The thermoelectric generator for generating electricity from the temperature differential between the first fluid and the second fluid of claim 1, wherein the thermoelectric generator further comprises:

a compression mechanism, wherein the compression mechanism is operably coupled with two of the plurality of second thermal modules such that the first thermal module and at least one of the plurality of thermoelectric modules is compressed between two of the plurality of second thermal modules.

3. The thermoelectric generator for generating electricity from the temperature differential between the first fluid and the second fluid of claim 2, wherein:

the compression mechanism comprises a rod and a spring.

4. The thermoelectric generator for generating electricity from the temperature differential between the first fluid and the second fluid of claim 2, wherein:

the compression mechanism is configured to compress with an actively variable force.

5. The thermoelectric generator for generating electricity from the temperature differential between the first fluid and the second fluid of claim 2, wherein:

the compression mechanism is configured to compensate for thermal expansion and thermal contraction of at least one of the plurality of second thermal modules.

6. The thermoelectric generator for generating electricity from the temperature differential between the first fluid and the second fluid of claim 2, wherein:

the compression mechanism is configured to compensate for stack tolerance build-up of the plurality of second thermal modules.

7. The thermoelectric generator for generating electricity from the temperature differential between the first fluid and the second fluid of claim 1, wherein;

at least one of the plurality of second thermal modules is compliantly coupled with at least one other of the plurality of second thermal modules.

8. The thermoelectric generator for generating electricity from the temperature differential between the first fluid and the second fluid of claim 7, wherein at least one of the plurality of second thermal modules being compliantly coupled with at least one other of the plurality of second thermal modules comprises:

at least one of the plurality of second thermal modules compliantly coupled with at least one other of the second thermal modules, allowing all axis expansion, contraction and natural mechanical variance in elements of a stack comprising at least one of the plurality of thermoelectric modules.

9. The thermoelectric generator for generating electricity from the temperature differential between the first fluid and the second fluid of claim 7, wherein at least one of the plurality of second thermal modules being compliantly coupled with at least one other of the plurality of second thermal modules comprises:

at least one of the plurality of second thermal modules being coupled via an o-ring slip joint with at least one other of the plurality of second thermal modules.

10. The thermoelectric generator for generating electricity from a temperature differential between a first fluid and a second fluid as recited in claim 1, wherein the first fluid is at a higher temperature than the second fluid.

11. The thermoelectric generator for generating electricity from a temperature differential between a first fluid and a second fluid as recited in claim 1, wherein the first fluid and the second fluid are received from external storage reservoirs.

12. The thermoelectric generator for generating electricity from a temperature differential between a first fluid and a second fluid as recited in claim 1, wherein the first fluid and the second fluid circulate to and from external storage reservoirs.

13. The thermoelectric generator for generating electricity from a temperature differential between a first fluid and a second fluid as recited in claim 1, further comprising an inlet through which the second fluid is received for distribution to all of the second thermal modules.

14. The thermoelectric generator for generating electricity from a temperature differential between a first fluid and a second fluid as recited in claim 1, wherein both fluids are liquids.

15. The thermoelectric generator for generating electricity from a temperature differential between a first fluid and a second fluid as recited in claim 14, wherein both liquids comprise water.

16. The thermoelectric generator for generating electricity from a temperature differential between a first fluid and a second fluid as recited in claim 1, wherein the first thermal module is rectangular.

17. The thermoelectric generator for generating electricity from a temperature differential between a first fluid and a second fluid as recited in claim 1, wherein each of the second thermal modules is rectangular.

18. The thermoelectric generator for generating electricity from a temperature differential between a first fluid and a second fluid as recited in claim 1, wherein the two second thermal modules that are on one side of the first thermal module are flexibly coupled to each other such that the second fluid flows through the respective second passages of both of the second thermal modules that are on one side of the first thermal module.

19. The thermoelectric generator for generating electricity from a temperature differential between a first fluid and a second fluid as recited in claim 18, further comprising a compliant member that seals between the two respective second passages.

22. The thermoelectric generator for generating electricity from a temperature differential between a first fluid and a second fluid as recited in claim 1, wherein at least two of the plurality of second thermal modules reside on a second side of the first thermal module, both of their respective thermoelectric modules being in contact with a second planar face of the first thermal module.

24. The thermoelectric generator for generating electricity from the temperature differential between the first fluid and the second fluid of claim 1, wherein:

the first block is rectangular; and

each second block is rectangular.

20. A thermoelectric generator for generating electricity from a temperature differential between a first fluid and a second fluid, the thermoelectric generator comprising:

a plurality of thermoelectric modules, wherein;

each of the thermoelectric modules comprises a first side and a second side; and

each of the thermoelectric modules generates electricity when there is a difference in temperature between the first side and the second side;

a first thermal module, wherein;

the first thermal module comprises a first block including a first passage through which the first fluid flows through the first block; and

the first thermal module is configured to exchange heat with the first sides of at least two of the plurality of thermoelectric modules;

a plurality of second thermal modules, wherein;

each of the plurality of second thermal modules comprises a respective second block including a respective second passage through which the second fluid flows through the respective second block; and

a side of each of the second thermal modules is configured to exchange heat with exactly one of the thermoelectric modules through the second side of the respective thermoelectric module;

at least two of the plurality of second thermal modules reside on one side of the first thermal module, both of their respective thermoelectric modules being in contact with one planar face of the first thermal module; and

each of the second thermal modules accommodates all axis mechanical variance in its respective thermoelectric module; and

a compliant member between the two second thermal modules that are on one side of the first thermal module, and a mechanism that connects the two second thermal modules and applies pressure to the compliant member.

21. The thermoelectric generator for generating electricity from a temperature differential between a first fluid and a second fluid as recited in claim 20, wherein the mechanism is a dogleg feature.

23. A thermoelectric generator for generating electricity from a temperature differential between a first fluid and a second fluid, the thermoelectric generator comprising:

a plurality of thermoelectric modules, wherein;

each of the thermoelectric modules comprises a first side and a second side; and

each of the thermoelectric modules generates electricity when there is a difference in temperature between the first side and the second side;

a first thermal module, wherein;

the first thermal module comprises a first block including a first passage through which the first fluid flows through the first block; and

the first thermal module is configured to exchange heat with the first sides of at least two of the plurality of thermoelectric modules;

a plurality of second thermal modules, wherein;

each of the plurality of second thermal modules comprises a respective second block including a respective second passage through which the second fluid flows through the respective second block; and

a side of each of the second thermal modules is configured to exchange heat with exactly one of the thermoelectric modules through the second side of the respective thermoelectric module; and

each of the second thermal modules accommodates all axis mechanical variance in its respective thermoelectric module; and

a compression mechanism that includes a rod, wherein the rod passes through the first thermal module without encountering the first passage, and wherein the rod passes through at least one of the second thermal modules without encountering any second passage.

25. A thermoelectric generator for generating electricity from a temperature differential between a first fluid and a second fluid, the thermoelectric generator comprising:

a plurality of thermoelectric modules, wherein;

each of the thermoelectric modules comprises a first side and a second side; and

each of the thermoelectric modules generates electricity when there is a difference in temperature between the first side and the second side;

a first thermal module, wherein;

the first thermal module comprises a first block including a first passage through which the first fluid flows through the first block; and

the first thermal module is configured to exchange heat with the first sides of at least two of the plurality of thermoelectric modules; and

a plurality of second thermal modules, wherein;

each of the plurality of second thermal modules comprises a respective second block including a respective second passage through which the second fluid flows through the respective second block; and

a side of each of the second thermal modules is configured to exchange heat with exactly one of the thermoelectric modules through the second side of the respective thermoelectric module; and

each of the second thermal modules accommodates all axis mechanical variance in its respective thermoelectric module; and

wherein the first fluid enters and exits the first thermal module via the same face of the first thermal module.

26. A thermoelectric generator for generating electricity from a temperature differential between a first fluid and a second fluid, the thermoelectric generator comprising:

four thermoelectric modules, wherein;

each of the thermoelectric modules comprises a first side and a second side; and

each of the thermoelectric modules generates electricity when there is a difference in temperature between the first side and the second side;

a first thermal module, wherein;

the first thermal module comprises a first passage through which the first fluid flows through the first thermal module; and

the first thermal module is configured to exchange heat with the first sides of the four thermoelectric modules, two of the four thermoelectric modules being in contact with a first side of the first thermal module, and two of the four thermoelectric modules being in contact with a second side of the first thermal module opposite the first side of the first thermal module; and

a plurality of second thermal modules, wherein;

each of the plurality of second thermal modules comprises a respective second passage through which the second fluid flows through the respective second thermal module; and

a side of each of the second thermal modules is configured to exchange heat with exactly one of the thermoelectric modules through the second side of the respective thermoelectric module; and

wherein at least some of the second fluid flows from an inlet, through a first one of the second thermal modules on the first side of the first thermal module, then through a second one of the second thermal modules on the first side of the first thermal module, and then to an outlet, and wherein the first one of the second thermal modules and the second one of the second thermal modules are flexibly coupled together;

and wherein the first fluid enters and exits the first thermal module via the same face of the first thermal module.

27. A thermoelectric generator for generating electricity from a temperature differential between a first fluid and a second fluid, the thermoelectric generator comprising:

an input fluid port;

an output fluid port;

a first thermal module;

a plurality of second thermal modules, each having a respective passage therethrough, through which a fluid can flow through the respective second thermal module; and

a plurality of thermoelectric modules;

wherein;

each of the plurality of thermoelectric modules has a least one face in contact with the first thermal module;

each of the plurality of second thermal modules has a respective face in contact with exactly one of the thermoelectric modules, such that each thermoelectric module is sandwiched between the first thermal module and a respective one of the second thermal modules;

a first pair of the second thermal modules is disposed on a first side of the first thermal module such that their respective passages align, such that the fluid can pass from the inlet fluid port, through the first pair of second thermal modules in series, and to the outlet fluid port; and

a second pair of the second thermal modules is disposed on a second side of the first thermal module opposite the first side of the first thermal module, such that the fluid can pass from the inlet fluid port, through the second pair of second thermal modules in series, and to the outlet fluid port.