Thermal Design Example For ME5390

Dr.
HoSung Lee
Thermal Design Examples

Heat Sinks
Thermoelectric coolers and generators
Heat Pipes
Compact Heat Exchangers
Solar Cells
Heat Sinks
Thermoelectric Generators and Coolers

Heat Absorbed
p
n
p
n-type Semiconductor
p-type Semiconcuctor
Negative (-)
Electrical Insulator (Ceramic)
Positive (+)
Electrical Conductor (copper)
Heat Rejected
Thermoelectric Generator
Heat Pipes
Solar Cells
Sun-tracking panels
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
p-type Semiconcuctor
Negative (-)
Electrical Insulator (Ceramic)
Positive (+)
Electrical Conductor (copper)
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 coefficientof-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
33
Dimensions for Butterfly Package
34

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 ZT2=1

T*
1.0
1.0
1.0
1.005
1.005
1.005
1.01
1.01
1.01
1.015
1.015
1.015
1.02
Nh
0.1
1.0
10.0
0.1
1
10
0.1
1
10
0.1
1
10
0.1
Rr
0.000
0.000
0.000
1.564
1.564
1.564
1.564
1.564
1.42
1.564
1.416
1.421
1.564
Nk
0.000
0.000
0.000
0.063
0.063
0.063
0.063
0.063
0.65
0.063
0.356
0.649
0.063
th
0.000
0.000
0.000
4.36E-04
7.27E-04
7.80E-04
8.70E-04
1.45E-03
8.51E-04
1.30E-03
1.28E-03
1.28E-03
1.74E-03
W n*
0.000
0.000
0.000
9.72E-08
2.71E-07
3.12E-07
3.88E-07
1.08E-06
3.89E-06
8.73E-07
4.82E-06
8.75E-06
1.55E-06
T 1*
0.000
1.000
1.000
1.003
1.005
1.005
1.006
1.009
1.01
1.008
1.011
1.014
1.011
T2*
0.000
1.000
1.000
1
1
1
1
1.001
1.005
1.001
1.004
1.007
1.001
NI
0.000
0.000
0.000
9.93E-04
1.66E-03
1.78E-03
1.99E-03
3.32E-03
2.05E-03
2.98E-03
3.09E-03
3.08E-03
3.97E-03
NV
0.000
0.000
0.000
1.55E-03
2.60E-03
2.78E-03
3.11E-03
5.19E-03
2.92E-03
4.66E-03
4.38E-03
4.38E-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 halflife 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 Cars Range
Buyers considering an electric car must bear in mind that using

battery-powered heating and air conditioning can decrease the cars
range by a third or more (see BMWs Solution to Limited ElectricVehicle 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 Fords 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 adsorbanta 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 Cars 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. The system requires very little electricityjust enough to run a small pump
and fans to blow cool or warm air.
Eventually the adsorbant cant take in any more water, but the system can be recharged by heating
the adsorbant above 200 C. This causes it to release the water, which is condensed and returned to a
reservoir.
An electric heater could be used for this purpose, says Evelyn Wang, a professor of mechanical
engineering at MIT, who is leading the work. But there so many sources of heat, such as heat from a
solar water heaterso electricity wouldnt have to be used, she says. Fully recharging the system is
expected to take about four hours, which is about what it takes to recharge some common electric
vehicles at standard charging stations.
The basic concept behind the temperature control system isnt new (see Using Heat to Cool
Buildings). But its been difficult to make such a system compact enough for use in a car, especially
because separate containers are normally used for evaporating and condensing the coolant. The
researchers more compact design uses one container for both purposes.
The researchers are now developing materials that can adsorb more water, which would make it
possible to use less adsorbant. One is a modified zeolite, a type of porous material that has long been
used in catalysis. Theyre also working on a material called a metal organic framework, whose
properties can be systematically changed by varying the composition of organic materials that link
microscopic clusters of metal. The researchers have added highly thermally conductive materials such
as carbon-based nanomaterials to their adsorbant so the system can heat and cool more rapidly,
which can also make it possible to shrink its overall size.
69
Solar Evacuated Tube Collector

(heat pipe)
70
Solar Heat Pipe TEG
71
Heat Fins Along Pipeline

Melted permafrost could result in sinking or
collapse of pipeline
72
Pipeline Cross Section

Heat Fins
Heat Pipes
Hot Oil Flow
Heat Conducts
Down Support
Beams
Condensation and
Evaporation of
Ammonia
Permafrost
73
Heat Pipe Glove

frostbite prevention
74
Heat Pipe Exchanger
75
76
Plate Heat Exchanger
77
78
Thermoelectric Cooler
79
Thermoelectric
cooler
80
Car seat climate control
81
82
CLIMATE CONTROL .Thermoelectric based

cooling/heating
83
84
USS DOLPHIN AGSS 555 Thermoelectric

Air Conditioning Test for Silent Running
85
Spacecraft Using Radioisotope

Thermoelectric Generators
86
87
88
Thermoelectric generator module
89
TEG Simulations (ANSYS)
90
TEG Temperature Simulations
91
92
Shell and Tube Heat Exchanger
Baffles
Tubes
Shell fluid
constrained
Tube fluid
93
Mesh Application Corrections
94
Vectors of Velocity Magnitude
95
Hand phone charger by body heat
96
Personal Mini Cooler

Personal Mini Cooler
thermoelectric cool/heat mini cooler
Specifications: Dimensions: 2.75 (width) X
1.20 (thick) X 5.60 (height) Inches Cold
Temperature: Up to 25 below Ambient
Temperature Weight: 4.00 oz.(without
batteries) Blue Disk: Polished & Anodized
Aluminum,1.4 inch diameter Blue Disk
Power: Four AA size NICKEL-METAL
HYDRIDE (Ni-MH).1200 mA rechargeable
Batteries.(Not supplied) or regular
AAEnergizer type batteries Case: ABS
Plastic
97
Dispenser-Printed TEG
Characteristics
Planar thick film (strip)
TEG properties:
Dimensions 5
640 90
Material and at 302
Size of one TEG strip
N-type: Bi2Te3 epoxy composite

( = . )
P-type: Sb2Te3 epoxy composite
( = . )
Manufacturing method
Dispense printing
Primary materials mixed with
epoxy resins to form inks
Size of TEG strips

stacked in parallel
Performance of Thermoelectric materials
99
Si Nanowires,
(Nature Vol. 451, 2008, Caltech and UC Berkeley)
Silicon bulk
ZT 0.01
Silicon nanowires ZT 1
100
Thermoelectric Cooler driven

by Solar Cells
101
Solar Driven Thermoelectric

Cooling Headgear
102
Hybrid Solar Cell and TEG
103
TEG with Solar Collector
104
Heat Pipes for Cooling Microprocessor
105
Solar Thermoelectric Generators
106
107
Miniature Thermoelectric Devices
RMT
Snyder et al. (2003)
Thermoelectric Devices
Miniature Thermoelectric Devices

TEC
TEG
110
111
Seat climate technology: We set

tomorrow's standards for comfort
Car Seat Cooling/Heating
112
Low-Grade (100 C) Heat Recovery
113
The End
114

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Dr.

Thermal Design Examples

Thermoelectric Generators and Coolers

Electrical Insulator (Ceramic)

Electrical Conductor (copper)

Compact Heat Exchangers

Solar Thermoelectric Generator (STEG)

Solar Thermoelectric Generator

Thermoelectric Modules (old & modern)

Kerosene lamp and radio

Thermoelectric Cooler Module

Electrical Insulator (Ceramic)

Electrical Conductor (copper)

System Designers having difficulties

Solar Thermoelectric Generator

Thermoelectric Heat Exchanger

Thermoelectric Heat Exchanger

devices into a large-capacity liquid heat exchanger (up to 100 kW).

HYBRID SOLAR PANEL DIAGRAM

Air-to-Air Thermoelectric Heat

Air-to-solid Thermoelectric Heat

Liquid-to-air Thermoelectric Heat

Cold Plate Cooler

Microprocessor Cooling (160W)

Miniature Thermoelectric Coolers

Thermoelectric Cooler for Telecom

Butterfly Package for Telecom Laser

Butterfly Package for Telecom Laser

Dimensions for Butterfly Package

Butterfly Package for Telecom Laser

Isometric View (ANSYS)

High-Tech Radio inside the

Remote Thermoelectric Generator

Thermoelectric Cooling Helmet

Thermoelectric Exhaust Systems

Waste Heat Recovery

Auto Exhaust Can Generate

Automotive Air Conditioning

Automotive Thermoelectric Air Conditioner (TEAC)

OTEC (Ocean Thermal Energy Conversion)

Bi-Te element size: 10 x 1.5 mm.

Develop Tables for Optimal Design

Table 1 Optimal Power Output for ZT2=1

Radioisotope Thermoelectric Generator

Curiosity Rover in Mars

plutonium with a halflife of about 87 years

Schematic Diagram of an RTG

RTG Applications in Industry

desirable power source for

includes the battery and

Waste Heat Recovery

Home Power Station

TEG installation on Stove

Heat Pipes in a Laptop Computer

Heat Pipes for Cooling in a Laptop

Novel Heating System Could Improve Electric Cars Range

Buyers considering an electric car must bear in mind that using

Power saver: A proof-of-concept heating

Novel Heating System Could Improve Electric Cars Range