Thermoelectric-based power generation systems and methods

• US 9,276,188 B2
• Filed: 01/10/2014
• Issued: 03/01/2016
• Est. Priority Date: 07/24/2009
• Status: Expired due to Fees

• Current Assignee: Gentherm Incorporated
• Original Assignee: Gentherm Incorporated
• Inventors: Bell, Lon E., Crane, Douglas T., LaGrandeur, John, van Heerden, David
• Primary Examiner(s): Tran, Binh Q
• Application Number:
  US14/152,741
• Publication Number:
  US 20140224291A1
• Time in Patent Office: 781 Days
• Field of Search: 602/74, 602/75, 602/92, 602/98, 603/00, 603/20, 603/21, 603/24, 165/51, 165/52
• US Class Current: 1/1
• CPC Class Codes: F01N 2240/14 a fuel burner
• CPC Class Codes: F01N 2240/36 an exhaust flap
• CPC Class Codes: F01N 2410/02 in case of high temperature, e.g. overheating of catalytic reactor
• CPC Class Codes: F01N 2410/10 for reducing flow resistance, e.g. to obtain more engine power
• CPC Class Codes: F01N 3/043 without contact between liquid and exhaust gases
• CPC Class Codes: F01N 3/2013 using electric or magnetic heating means
• CPC Class Codes: F01N 3/2053 By-passing catalytic reactors, e.g. to prevent overheating
• CPC Class Codes: F01N 5/025 the device being thermoelectric generators
• CPC Class Codes: F28D 21/0003 the heat being recuperated from exhaust gases F28D21/0014 takes precedence
• CPC Class Codes: F28D 7/106 consisting of two coaxial conduits or modules of two coaxial conduits
• CPC Class Codes: H10N 10/00 Thermoelectric devices comprising a junction of dissimilar materials, i.e. devices exhibiting Seebeck or Peltier effects integrated devices or assemblies of multiple devices H10N19/00
• CPC Class Codes: H10N 10/13 characterised by the heat-exchanging means at the junction
• CPC Class Codes: H10N 10/17 characterised by the structure or configuration of the cell or thermocouple forming the device
• CPC Class Codes: Y02E 20/14 Combined heat and power generation [CHP]
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

Some embodiments provide a waste heat recovery apparatus including an exhaust tube having a cylindrical outer shell configured to contain a flow of exhaust fluid; a first heat exchanger extending through a first region of the exhaust tube, the first heat exchanger in thermal communication with the cylindrical outer shell; a second region of the exhaust tube extending through the exhaust tube, the second region having a low exhaust fluid pressure drop; an exhaust valve operatively disposed within the second region and configured to allow exhaust fluid to flow through the second region only when a flow rate of the exhaust fluid becomes great enough to result in back pressure beyond an allowable limit; and a plurality of thermoelectric elements in thermal communication with an outer surface of the outer shell.

Claims

1. A power generation apparatus for a vehicle having an engine, the apparatus comprising:

at least one exhaust conduit configured to contain a flow of engine exhaust fluid, the at least one exhaust conduit comprising a first region having a first exhaust fluid pressure drop and a second region having a second exhaust fluid pressure drop less than the first exhaust fluid pressure drop;

at least one heat exchanger in thermal communication with engine exhaust fluid in the first region;

an array of thermoelectric elements in thermal communication with the at least one heat exchanger;

a heat transfer enhancement structure within the second region and in thermal communication with the array of thermoelectric elements, the heat transfer enhancement structure configured to transfer heat from the exhaust fluid in the second region;

at least one valve configured to adjust engine exhaust fluid flow through the first region and the second region; and

a controller configured to actuate the at least one valve based on at least one engine operating parameter.

2. The apparatus of claim 1, wherein the at least one engine operating parameter is selected from a group consisting of:

engine exhaust fluid flow rate, engine exhaust backpressure, and heat extraction from the exhaust fluid.

3. The apparatus of claim 1, wherein the engine comprises an electrical device configured to receive electrical power from the array of thermoelectric elements.

4. The apparatus of claim 1, wherein the controller is configured to actuate the at least one valve to allow engine exhaust fluid to flow through the second region upon an engine exhaust flow rate being great enough to result in back pressure of the apparatus greater than a predetermined back pressure limit.

5. The apparatus of claim 1, wherein the controller is configured to actuate the at least one valve to apportion engine exhaust fluid flow between the first region and the second region to keep back pressure of the apparatus within predetermined limits while optimizing heat extraction from the engine exhaust fluid under operating ranges of engine exhaust fluid temperature and engine exhaust fluid mass flow rate.

6. The apparatus of claim 1, further comprising at least one coolant conduit in thermal communication with the array of thermoelectric elements, the at least one coolant conduit comprising an inner tube and an outer tube in thermal communication with one another, wherein the outer tube has a greater diameter than the inner tube.

7. The apparatus of claim 1, further comprising a sleeve between the first region and the second region, the sleeve in thermal communication with the heat transfer enhancement structure in the second region and the at least one heat exchanger in the first region.

8. The apparatus of claim 7, wherein the heat transfer enhancement structure comprises a plurality of fins in thermal communication with the sleeve, wherein the heat transferred from the exhaust fluid in the second region by the plurality of fins is directed through the sleeve to the array of thermoelectric elements via the at least one heat exchanger in the first region.

9. The apparatus of claim 1, wherein the first region and the second region are configured to allow parallel fluid flow of the engine exhaust fluid through the first region and the second region.

10. The apparatus of claim 1, wherein the at least one exhaust conduit comprises an exhaust tube, the second region comprising a central portion within the exhaust tube and the first region comprising a peripheral portion within the exhaust tube.

22. The apparatus of claim 2, wherein the at least one heat exchanger comprises fins.

23. The apparatus of claim 2, wherein the heat enhancement structure is braised to an inner sleeve of the at least one heat exchanger, the inner sleeve lining an inside surface of the at least one heat exchanger.

24. The apparatus of claim 2, wherein the heat enhancement structure is integral to an inner sleeve of the at least one heat exchanger, the inner sleeve lining an inside surface of the at least one heat exchanger.

11. A method of generating electric power in a vehicle comprising an engine, the method comprising:

flowing an engine exhaust fluid through at least one exhaust fluid conduit of a power generation system, the at least one exhaust conduit comprising a first region having a first exhaust fluid pressure drop and a second region having a second exhaust fluid pressure drop less than the first exhaust fluid pressure drop, the power generation system comprising at least one heat exchanger in thermal communication with the exhaust fluid in the first region, an array of thermoelectric elements in thermal communication with the at least one heat exchanger, a heat transfer enhancement structure within the second region and in thermal communication with the array of thermoelectric elements, the heat transfer enhancement structure configured to transfer heat from the exhaust fluid in the second region, and at least one valve configured to adjust engine exhaust fluid flow through the first region and the second region; and

actuating the at least one valve based on at least one engine operating parameter.

12. The method of claim 11, wherein the at least one engine operating parameter is selected from a group consisting of:

engine exhaust fluid flow rate, engine exhaust backpressure, and heat extraction from the exhaust fluid.

13. A power generation apparatus, the apparatus comprising:

at least one exhaust conduit configured to contain a flow of exhaust fluid, the at least one exhaust conduit comprising a first region having a first exhaust fluid pressure drop and a second region having a second exhaust fluid pressure drop less than the first exhaust fluid pressure drop;

at least one first heat exchanger in thermal communication with exhaust fluid in the first region;

at least one second heat exchanger in thermal communication with exhaust fluid in the second region and with the at least one first heat exchanger;

at least one thermoelectric element in thermal communication with the at least one first heat exchanger; and

at least one valve configured to be actuated to apportion exhaust fluid flow among the first region and the second region.

14. The apparatus of claim 13, further comprising a controller operably coupled to the at least one valve, the controller configured to adjust the at least one valve based on at least one operating parameter of an engine operably coupled to the apparatus.

15. The apparatus of claim 14, wherein the at least one operating parameter is selected from a group consisting of:

engine exhaust fluid flow rate, engine exhaust backpressure, and heat extraction from the exhaust fluid.

16. The apparatus of claim 13, wherein a first thermal path of heat from the exhaust fluid in the first region, through the at least one first heat exchanger, to the at least one thermoelectric element is shorter than a second thermal path of heat from the exhaust fluid in the second region, through the at least one second heat exchanger, through the at least one first heat exchanger, to the at least one thermoelectric element.

17. The apparatus of claim 13, wherein the at least one first heat exchanger is more dense than the at least one second heat exchanger.

18. The apparatus of claim 13, wherein the at least one first heat exchanger and the at least one second heat exchanger are separated by a thermally conductive sleeve.

19. A method of generating electric power, the method comprising:

flowing an exhaust fluid through at least one exhaust conduit of a power generation system, the at least one exhaust conduit comprising a first region having a first exhaust fluid pressure drop and a second region having a second exhaust fluid pressure drop less than the first exhaust fluid pressure drop, the power generation system comprising;

at least one first heat exchanger in thermal communication with exhaust fluid within the first region;

at least one second heat exchanger in thermal communication with exhaust fluid within the second region and with the at least one first heat exchanger;

at least one thermoelectric element in thermal communication with the at least one first heat exchanger; and

at least one valve configured to apportion exhaust fluid flow among the first region and the second region;

transferring heat from the exhaust fluid in the first region to the at least one thermoelectric element via the at least one first heat exchanger; and

transferring heat from the exhaust fluid in the second region to the at least one thermoelectric element via the at least one second heat exchanger and the at least one first heat exchanger.

20. The method of claim 19, wherein the exhaust fluid is received from an engine, and the method further comprises actuating the at least one valve based on at least one operating parameter of the engine.

21. The method of claim 20, wherein the at least one operating parameter is selected from a group consisting of:

exhaust fluid flow rate, exhaust backpressure, and heat extraction from the exhaust fluid.