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Thermal Design Example for ME5390.Pdf Dr. HoSung Lee 1 Thermal Design Examples Heat Sinks Thermoelectric coolers and generators Heat Pipes Compact Heat Exchangers Solar Cells 2 Heat Sinks 3 Thermoelectric Generators and Coolers Heat Absorbed p n p n-type Semiconductor n n p Positive (+) p n p-type Semiconcuctor p Negative (-) Electrical Conductor (copper) Electrical Insulator (Ceramic) Heat Rejected 4 Thermoelectric Generator 5 Heat Pipes 6 Compact Heat Exchangers 7 Solar Cells 8 Sun-tracking panels 9 10 Solar Thermoelectric Generator (STEG) 11 Solar Thermoelectric Generator 12 Kusatsu Hot-springs TEG System 13 Thermoelectric Modules (old & modern) 1950s 2012 Kerosene lamp and radio 14 15 16 17 Thermoelectric Cooler Module Heat Absorbed p n p n-type Semiconductor n n p Positive (+) p n p-type Semiconcuctor p Negative (-) Electrical Conductor (copper) Electrical Insulator (Ceramic) Heat Rejected System Designers having difficulties •Most of manufacturers do not provide the material properties (Manufacturers’ proprietary information) 18 Thermoelectric Modules 19 Solar Thermoelectric Generator Nature Materials 10, 532-538 (2011) 20 Thermoelectric Heat Exchanger 21 Thermoelectric Heat Exchanger This study investigates the feasibility of integrating thermoelectric devices into a large-capacity liquid heat exchanger (up to 100 kW). Typically, thermal-electrical conversion is inefficient and thermoelectrics are only used in low-power applications (<1 kW). The incentive for using thermoelectrics, however, lies in their compact size, light-weight, high reliability, and sub-ambient cooling. In this study, a subscale thermoelectric heat exchanger is designed (see Fig. 1), fabricated and optimized for performance through testing and simulation. Specifically, direct fluid contact and jet-impingement were used to improve heat transfer at both hot and cold junctions of the thermoelectric. A schematic of the design concept can be seen in Fig. 2. This approach resulted in a five-fold increase in the cooling coefficient- of-performance. Experimentally validated predictions also demonstrated that a 100-kW heat exchanger is lighter per unit-power than comparable vapor-compression systems. This feasibility study raises the outlook of reducing thermoelectric technology to practice in large heat load applications. 22 HYBRID SOLAR PANEL DIAGRAM HYBRID SOLAR PANEL DIAGRAM The hybrid solar panel that Yin designed has as its outermost layer a clear protective cover, followed by a layer of thermoelectric material, a layer with plastic tubes (called the functionally graded material interlayer) to carry water that will cool the other layers while also carrying away heated water, and a bottom layer of reinforcing plastic. Image: © COLUMBIA UNIVERSITY 23 Air-to-Air Thermoelectric Heat Exchangers BSST's parent company, ships more than 1.2 million thermoelectric Air to Air devices to automobile seat manufacturers annually, making possible the cooled and heated car seats available on many car models. Building on this technology and manufacturing expertise, BSST has created Air to Air devices that provide electronic enclosure cooling at nearly double the efficiency of standard thermoelectric cooling devices. 24 Air-to-solid Thermoelectric Heat Exchangers 25 Liquid-to-air Thermoelectric Heat Exchanger BSST's uniquely designed Liquid to Air systems allow for significant cooling power in a variety of form factors. In a typical BSST configuration, ambient air enters the device and is instantly chilled to approximately 15 degrees Celsius. The air is then blown over electronic systems or critical components. The waste heat from the process is removed by the liquid loop (typically water, but other fluids can be used). 26 Cold Plate Cooler 27 Bio-medical Experiment Two-Temperature Reference TEC 28 Microprocessor Cooling (160W) 29 Miniature Thermoelectric Coolers 30 Thermoelectric Cooler for Telecom Laser 31 Butterfly Package for Telecom Laser 32 Butterfly Package for Telecom Laser 33 Dimensions for Butterfly Package 34 Butterfly Package for Telecom Laser Small sized Relatively low price Long lifetime 35 Isometric View (ANSYS) 36 Laser Butterfly 37 Laser Butterfly 38 High-Tech Radio inside the Wing of a Fighter Aircraft 39 Remote Thermoelectric Generator Power generation: 120 Watts Fuel: natural gas 40 Thermoelectric Cooling Helmet 41 42 Thermoelectric Exhaust Systems 43 44 Waste Heat Recovery 45 Auto Exhaust Can Generate Thermoelectric Power About 40 percent of the energy from gasoline or diesel fuel is wasted as exhaust heat. If you can convert some of that heat to electricity, it can provide electric power for automotive accessories, relieving some of the burden from the engine resulting in better fuel economy. The device that performs this conversion is a thermoelectric generator and GM has been working on developing one to either assist or even replace the vehicle's alternator. 46 47 Automotive Air Conditioning 48 Automotive HVAC 49 Automotive Thermoelectric Air Conditioner (TEAC) 50 OTEC (Ocean Thermal Energy Conversion) Bi-Te element size: 10 x 1.5 mm. Total number of n-p couples: 10,000 couples/ Number of TEG modules: 500 modules. 51 Develop Tables for Optimal Design Table 1 Optimal Power Output for ZT∞2=1 T∞* Nh Rr Nk ηth Wn* T1* T2* NI NV 1.0 0.1 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 1.0 1.0 0.000 0.000 0.000 0.000 1.000 1.000 0.000 0.000 1.0 10.0 0.000 0.000 0.000 0.000 1.000 1.000 0.000 0.000 1.005 0.1 1.564 0.063 4.36E-04 9.72E-08 1.003 1 9.93E-04 1.55E-03 1.005 1 1.564 0.063 7.27E-04 2.71E-07 1.005 1 1.66E-03 2.60E-03 1.005 10 1.564 0.063 7.80E-04 3.12E-07 1.005 1 1.78E-03 2.78E-03 1.01 0.1 1.564 0.063 8.70E-04 3.88E-07 1.006 1 1.99E-03 3.11E-03 1.01 1 1.564 0.063 1.45E-03 1.08E-06 1.009 1.001 3.32E-03 5.19E-03 1.01 10 1.42 0.65 8.51E-04 3.89E-06 1.01 1.005 2.05E-03 2.92E-03 1.015 0.1 1.564 0.063 1.30E-03 8.73E-07 1.008 1.001 2.98E-03 4.66E-03 1.015 1 1.416 0.356 1.28E-03 4.82E-06 1.011 1.004 3.09E-03 4.38E-03 1.015 10 1.421 0.649 1.28E-03 8.75E-06 1.014 1.007 3.08E-03 4.38E-03 1.02 0.1 1.564 0.063 1.74E-03 1.55E-06 1.011 1.001 3.97E-03 6.21E-03 52 Radioisotope Thermoelectric Generator (RTG) 53 Curiosity Rover in Mars 54 MMRTG cutaway 55 56 Plutonium 238 Radioactive isotope of plutonium with a half- life of about 87 years and is a very powerful alpha ray emitter 57 RTG The heat produced by the decay of Plutonium-238 can be converted to electricity by a TEG 58 Schematic Diagram of an RTG System 59 RTG Applications in Industry RTGs are usually the most desirable power source for unmanned or unmaintained situations requiring small amount of power for durations too long for fuel cells, batteries and generators Satellites Space Probes Unmanned Remote Facilities Lighthouse Beacons 60 Pacemaker The latest pacemakers are powered by radioactive isotopes for long life and weigh no more than 15 g and about 3 cm in diameter. The cost is about $10,000 to $15,000 It is made up of two parts: A pulse generator, which includes the battery and several electronic circuits Wires, called leads, which are attached to the heart wall 61 Waste Heat Recovery Geothermal Energy 62 Home Power Station One possible use for thermoelectric generators is to provide supplemental or back-up electricity for home owners who use outdoor wood/biofuel furnaces. 63 TEG installation on Stove 64 Heat Pipes in a Laptop Computer 65 Heat Pipes for Cooling in a Laptop 66 Design Temperature control of CPU 67 Novel Heating System Could Improve Electric Car’s Range Buyers considering an electric car must bear in mind that using battery-powered heating and air conditioning can decrease the car’s range by a third or more (see “BMW’s Solution to Limited Electric- Vehicle Range: A Gas-Powered Loaner”). A New York Times reviewer recently ran into this problem on a test drive, ending up stranded with a dead battery (see “Musk-New York Times Debate Highlights Electric Cars’ Shortcomings”). But a heating and cooling system under development almost eliminates the drain on the battery. The researchers are working with Ford on a system that they hope to test in Ford’s Focus EV within the next two years. The work is being funded with a $2.7 million grant from the Advanced Research Projects Agency for Energy. The researchers describe their new device as a thermal battery. It uses materials that can store large amounts of coolant in a small volume. As the coolant moves through the system, it can be used for either heating or cooling. In the system, water is pumped into a low-pressure container, evaporating and absorbing heat in the process. The water vapor is then exposed to an adsorbant—a material with microscopic pores that have an affinity for water molecules. This material pulls the vapor out of the container, keeping the pressure low so more water can be pumped in and evaporated. This evaporative cooling process can be used to cool off the passenger compartment. Power saver: A proof-of-concept heating and cooling system for electric vehicles works without battery power. 68 Novel Heating System Could Improve Electric Car’s Range As the material adsorbs water molecules, heat is released; it can be run through a radiator and dissipated into the atmosphere when the system is used for cooling, or it can be used to warm up the passenger compartment.
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