Membrane-Supported Thermoelectric Generator

Solid-state thermoelectric (TE) devices provide many advantages in refrigeration (TE coolers) and power generation (TE generators). These highly reliable devices have no moving parts, operate over a large range of temperatures, and do not emit toxic or environmentally-unfriendly gases. These devices can be easily integrated into thermal energy conversion systems that meet NASA needs for innovative space power generation on orbiting platforms, extraterrestrial surfaces, and space transportation vehicles. To date, the adoption of TE generator (TEG) devices in energy scavenging/power recovery applications has been hampered by a lack of TE material compositions, no high throughput production methods for large-area conformable TEG devices, and high cost-per-unit area for tiling rigid plate TE devices. Production of large-area sheets of high-ZT TEG devices that conform to space vehicle and other relevant thermal gradient surfaces would be highly beneficial. This effort develops membrane-supported thermoelectric device manufacturing technology with in-situ sintering of high-ZT thermoelectric powders dispersed across a fiberglass sheet matrix serving as a mechanical support. The method provides intrinsic densification of the TE powders between the two faces of the fiberglass sheet and allows for large-scale conformable thermoelectric sheets to be produced with high performance at low cost.

Space power engineers can use these devices to produce custom fit power generation systems directly on surfaces with high temperature differences such as the hull of a space vehicle, satellite thermal busses, and extraterrestrial shelter materials. These large-area, integrated thermoelectric sheets will provide a means to maximize the extraction of otherwise wasted heat for both NASA and commercial applications such as automotive/aerospace exhaust systems, effluent piping, and petrochemical refining equipment. The proposed device embodiment is the only significant concept amendable to attachment to the contours and surfaces of space vehicles and as such will have a significant impact on generate power during space missions.

Unrecovered waste heat from energy-consuming industrial processes is estimated by the DOE at > 10 quads/yr (1 quad = 1015 BTU). Assuming a conservative 9 quads, 6% efficiency for TE devices constructed with our approach, 50% losses due to parasitic heat transfer losses and integration, and penetrating 10% of the waste heat market, we estimate an economically viable TE device could enable recovery of ~20 trillion BTU of waste heat/year. Additionally, the incorporation of TE devices in automobiles can improve the efficiency of their power system by up to 5%. This level of waste heat energy recovery would lower the average consumer gas consumption ~15-20 gallons with a cost savings on the order of $70?$100/year. A low-cost manufacturing solution would pay back in the first year, passing the savings onto the lifetime of the device, which based on non-moving parts, should be relatively long. The developed technology will lead to quasi-renewable energy recovery, or energy that would otherwise be radiated as waste environmental heat, resulting in a far-reaching impact on the world's energy consumption, including lowering the U.S. dependence on foreign oil. Next to solar energy, waste heat recovery is the most available secondary power source.

This is early/mid-stage (TRL 5) — the most realistic path in is NASA SBIR/STTR, which funds small businesses and research institutions to develop technology aligned with NASA's needs (equity-free, phased funding). Check whether a current SBIR/STTR solicitation topic overlaps with this project's technology area, or contact the project directly (above) to ask.

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