Cartridge-based thermoelectric systems

• US 9,293,680 B2
• Filed: 06/05/2012
• Issued: 03/22/2016
• Est. Priority Date: 06/06/2011
• Status: Expired due to Fees

• Current Assignee: Gentherm Incorporated
• Original Assignee: Gentherm Incorporated
• Inventors: Poliquin, Eric, Crane, Douglas T., Jovovic, Vladimir, Dean, Joseph, Kossakovski, Dmitri, LaGrandeur, John Walter
• Primary Examiner(s): Barton, Jeffrey T
• Assistant Examiner(s): Binkley, Meisha
• Application Number:
  US13/489,237
• Publication Number:
  US 20130104953A1
• Time in Patent Office: 1,386 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: F01N 5/025 the device being thermoelectric generators
• CPC Class Codes: F25B 21/04 reversible
• CPC Class Codes: F28D 7/106 consisting of two coaxial conduits or modules of two coaxial conduits
• CPC Class Codes: F28F 1/24 and extending transversely F28F1/38 takes precedence
• CPC Class Codes: F28F 2265/10 for preventing overheating, e.g. heat shields thermal insulation F28F2270/00
• CPC Class Codes: H01M 14/00 Electrochemical current or voltage generators not provided for in groups H01M6/00 - H01M12/00; Manufacture thereof
• 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: Y02T 10/12 Improving ICE efficiencies

Abstract

Cartridge-based thermoelectric assemblies and systems are provided which include at least one shunt configured to extend around a conduit, a plurality of thermoelectric elements in thermal communication and in electrical communication with the at least one shunt with at least a portion of the at least one shunt sandwiched between the at least one first thermoelectric element and the at least one second thermoelectric element. The thermoelectric elements are electrically isolated from the conduit. The thermoelectric assemblies and systems further include at least one heat exchanger in thermal communication with the at least one shunt and configured to be in thermal communication with a second fluid.

Claims

1. A thermoelectric system comprising:

at least a portion of a tube configured to allow a first fluid to flow through the at least a portion of the tube along an axial direction of the tube;

a first thermoelectric assembly and a second thermoelectric assembly, wherein each of the first thermoelectric assembly and the second thermoelectric assembly is in thermal communication with the tube and with a second fluid and comprises;

at least one first shunt extending around an outer perimeter of the tube generally perpendicularly to the axial direction;

at least one first thermoelectric element in thermal communication and in electrical communication with the at least one first shunt;

at least one second thermoelectric element in thermal communication and in electrical communication with the at least one first shunt, wherein at least a portion of the at least one first shunt is sandwiched between the at least one first thermoelectric element and the at least one second thermoelectric element, wherein the at least one first thermoelectric element and the at least one second thermoelectric element are electrically isolated from the tube; and

at least one heat exchanger in thermal communication with the at least one first shunt and in thermal communication with the second fluid, the at least one heat exchanger comprising a plurality of fins extending generally outwardly from the at least one first shunt;

at least one compliant element between and mechanically coupled to the at least one heat exchanger of the first thermoelectric assembly and the at least one heat exchanger of the second thermoelectric assembly; and

at least one second shunt extending around the outer perimeter of the tube generally perpendicularly to the axial direction and in thermal communication with the tube, wherein at least a portion of the at least one second shunt is electrically isolated from the tube and is in thermal communication with, in electrical communication with, and sandwiched between the at least one second thermoelectric element of the first thermoelectric assembly and the at least one first thermoelectric element of the second thermoelectric assembly,

wherein the first thermoelectric assembly, the at least one second shunt, and the second thermoelectric assembly are in series electrical communication with one another such that the thermoelectric system has an electrical current flow path through the at least one first thermoelectric element of the first thermoelectric assembly, the at least one first shunt of the first thermoelectric assembly, the at least one second thermoelectric element of the first thermoelectric assembly, the at least one second shunt, the at least one first thermoelectric element of the second thermoelectric assembly, the at least one first shunt of the second thermoelectric assembly, and the at least one second thermoelectric element of the second thermoelectric assembly.

2. The thermoelectric system of claim 1, wherein the current flow path is in a direction generally parallel to the axial direction.

3. The thermoelectric system of claim 1, wherein the at least one first shunt encircles the tube, and the at least one second shunt encircles the tube.

4. The thermoelectric system of claim 1, wherein each of the first thermoelectric assembly and the second thermoelectric assembly further comprises at least one electrically insulating layer electrically isolating the at least one first shunt from the at least one heat exchanger.

5. The thermoelectric system of claim 1, wherein at least one of the at least one heat exchanger of the first thermoelectric assembly and the at least one heat exchanger of the second thermoelectric assembly is compliant in response to motion among portions of the thermoelectric system.

6. The thermoelectric system of claim 1, wherein the at least one second shunt is configured to slide along the tube and to remain in thermal communication with the tube in response to thermal expansion or contraction within the thermoelectric system.

7. The thermoelectric system of claim 1, wherein the at least one second shunt is responsive to increases of temperature by increasing a compressive force in a radial direction applied to the tube.

8. The thermoelectric system of claim 1, wherein the current flow path passes once through the first thermoelectric assembly, the at least one second shunt, and the second thermoelectric assembly.

9. The thermoelectric system of claim 1, wherein the at least one first shunt comprises a first segment, a second segment, and an electrically insulating material between the first segment and the second segment, the at least one first thermoelectric element comprising at least one first p-type thermoelectric element and at least one first n-type thermoelectric element, the at least one second thermoelectric element comprising at least one second p-type thermoelectric element and at least one second n-type thermoelectric element, wherein the first segment of the at least one first shunt is sandwiched between the at least one first p-type thermoelectric element and the at least one second n-type thermoelectric element, and the second segment of the at least one first shunt is sandwiched between the at least one first n-type thermoelectric element and the at least one second p-type thermoelectric element.

10. The thermoelectric system of claim 1, wherein the at least one first shunt comprises a plurality of first segments with electrically insulating material between at least some of the first segments, the at least one first thermoelectric element comprising a plurality of p-type thermoelectric elements and a plurality of n-type thermoelectric elements, the at least one second thermoelectric element comprising a plurality of p-type thermoelectric elements and a plurality of n-type thermoelectric elements, wherein each first segment of the plurality of first segments is sandwiched between a thermoelectric element of the at least one first thermoelectric element and a thermoelectric element of the at least one second thermoelectric element having different doping types.

11. The thermoelectric system of claim 10, wherein the at least one second shunt comprises a plurality of second segments with electrically insulating material between at least some of the second segments, wherein each second segment of the plurality of second segments is sandwiched between a thermoelectric element of the at least one second thermoelectric element of the first thermoelectric assembly and a thermoelectric element of the at least one first thermoelectric element of the second thermoelectric assembly having different doping types.

12. The thermoelectric system of claim 1, wherein the fins of the plurality of fins extend generally outwardly from the at least one first shunt generally parallel to one another perpendicularly to the axial direction.

13. The thermoelectric system of claim 1, wherein at least some of the fins of the plurality of fins are planar in a plane generally parallel to the axial direction.

14. The thermoelectric system of claim 1, wherein at least some of the fins of the plurality of fins are planar in a plane perpendicular to the axial direction.

15. The thermoelectric system of claim 1, wherein the at least one compliant element is between and mechanically coupled to a first fin of the at least one heat exchanger of the first thermoelectric assembly and a second fin of the at least one heat exchanger of the second thermoelectric assembly.

16. The thermoelectric system of claim 1, wherein, the at least one compliant element is compliant in response to thermal expansion or contraction of the first thermoelectric assembly and the second thermoelectric assembly, the thermoelectric system further comprising a first cap extending around the tube at a first end of the thermoelectric system and a second cap extending around the tube at a second end of the thermoelectric system, wherein the first cap, the second cap, the at least one heat exchanger of the first thermoelectric assembly, the at least one heat exchanger of the second thermoelectric assembly, and the at least one compliant element form at least a portion of an enclosure containing the at least one first thermoelectric element and the at least one second thermoelectric element.

17. The thermoelectric system of claim 16, wherein the enclosure hermetically seals the at least one first thermoelectric element and the at least one second thermoelectric element within the enclosure.

18. A thermoelectric system comprising:

at least a portion of a tube having a first fluid flowing through the at least a portion of the tube along an axial direction of the tube;

a plurality of thermoelectric assemblies, wherein each thermoelectric assembly of the plurality of thermoelectric assemblies is in thermal communication with the tube and with a second fluid different from the first fluid and comprises;

at least one first shunt extending around an outer perimeter of the tube in a plane generally perpendicular to the axial direction;

at least one first thermoelectric element in thermal communication and in electrical communication with the at least one first shunt; and

at least one second thermoelectric element in thermal communication and in electrical communication with the at least one first shunt, wherein at least a portion of the at least one first shunt is sandwiched between the at least one first thermoelectric element and the at least one second thermoelectric element, wherein the at least one first thermoelectric element and the at least one second thermoelectric element are electrically isolated from the tube; and

a plurality of heat exchangers in thermal communication with the at least one first shunt, in thermal communication with the second fluid, and comprising a plurality of fins extending generally outwardly from the at least one first shunt;

at least one compliant element between and mechanically coupled to the plurality of heat exchangers of a first thermoelectric assembly of the plurality of thermoelectric assemblies and the plurality of heat exchangers of a second thermoelectric assembly of the plurality of thermoelectric assemblies; and

a plurality of second shunts, wherein each second shunt of the plurality of second shunts extends around the outer perimeter of the tube in a plane generally perpendicular to the axial direction and is in thermal communication with the tube, wherein at least a portion of each second shunt of the plurality of second shunts is electrically isolated from the tube and is in thermal communication with, in electrical communication with, and sandwiched between the first and second thermoelectric assemblies of the plurality of thermoelectric assemblies, wherein at least some of the plurality of thermoelectric assemblies and at least some of the plurality of second shunts are in series electrical communication with one another.

19. The thermoelectric system of claim 18, wherein the at least one first shunt of each thermoelectric assembly of the plurality of thermoelectric assemblies encircles the tube, and each second shunt of the plurality of second shunts encircles the tube.

20. The thermoelectric assembly of claim 18, wherein the plurality of thermoelectric assemblies and the plurality of second shunts alternate with one another along the axial direction, and an electrical current flow path through the plurality of thermoelectric assemblies and the plurality of second shunts is in a direction generally parallel to the axial direction.

21. The thermoelectric system of claim 18, wherein each thermoelectric assembly of the plurality of thermoelectric assemblies further comprises at least one electrically insulating layer electrically isolating the at least one first thermoelectric element from the conduit and electrically isolating the at least one second thermoelectric element from the tube.

22. The thermoelectric system of claim 18, wherein each compliant element of the at least one compliant element is sandwiched between and mechanically coupled to the pluralities of heat exchangers of two adjacent thermoelectric assemblies of the plurality of thermoelectric assemblies.

23. The thermoelectric system of claim 18, further comprising at least one electrically insulating layer between the pluralities of heat exchangers of two adjacent thermoelectric assemblies of the plurality of thermoelectric assemblies.

24. The thermoelectric system of claim 18, wherein at least one heat exchanger of the plurality of heat exchangers is compliant in response to motion among portions of the thermoelectric system.

25. The thermoelectric system of claim 18, wherein at least some second shunts of the plurality of second shunts are configured to slide along the tube and to remain in thermal communication with the tube in response to thermal expansion or contraction within the thermoelectric system.

26. The thermoelectric system of claim 18, wherein the plurality of second shunts is responsive to increases of temperature by increasing a compressive force in a radial direction applied to the tube.

27. The thermoelectric system of claim 18, wherein the fins of the plurality of fins extend generally outwardly from the at least one first shunt generally parallel to one another perpendicularly to the axial direction.

28. The thermoelectric system of claim 18, wherein at least some of the fins of the plurality of fins are planar in a plane generally parallel to the axial direction.

29. The thermoelectric system of claim 18, wherein at least some of the fins of the plurality of fins are planar in a plane perpendicular to the axial direction.

30. The thermoelectric system of claim 18, wherein the at least one compliant element is between and mechanically coupled to a first fin of the plurality of heat exchangers of the first thermoelectric assembly and a second fin of the plurality of heat exchangers of the second thermoelectric assembly.

31. The thermoelectric system of claim 18, further comprising a plurality of compliant elements that comprises the at least one compliant element, each compliant element of the plurality of compliant elements between and mechanically coupled to the plurality of heat exchangers of adjacent thermoelectric assemblies, a first cap extending around the tube at a first end of the thermoelectric system, and a second cap extending around the tube at a second end of the thermoelectric system, wherein the first cap, the second cap, the plurality of heat exchangers, and the plurality of compliant elements form at least a portion of an enclosure containing the first thermoelectric elements and the second thermoelectric elements.

32. The thermoelectric system of claim 31, wherein the enclosure hermetically seals the first thermoelectric elements and the second thermoelectric elements within the enclosure.

33. The thermoelectric system of claim 18, wherein the at least one first shunt comprises a plurality of first segments with electrically insulating material between the first segments, the at least one first thermoelectric element comprising a plurality of p-type thermoelectric elements and a plurality of n-type thermoelectric elements, the at least one second thermoelectric element comprising a plurality of p-type thermoelectric elements and a plurality of n-type thermoelectric elements, wherein each first segment of the plurality of first segments is sandwiched between a thermoelectric element of the at least one first thermoelectric element and a thermoelectric element of the at least one second thermoelectric element having different doping types.

34. The thermoelectric system of claim 33, wherein each second shunt of the plurality of second shunts comprises a plurality of second segments with electrically insulating material between at least some of the second segments, wherein each second segment of the plurality of second segments is sandwiched between a thermoelectric element of the at least one second thermoelectric element of the first thermoelectric assembly and a thermoelectric element of the at least one first thermoelectric element of the second thermoelectric assembly having different doping types.

35. The thermoelectric system of claim 34, wherein a current flow path through the thermoelectric system passes multiple times through each thermoelectric assembly of the plurality of thermoelectric assemblies and each second shunt of the plurality of second shunts.