Reinhard Sottong

Development of a Thermoelectric Module Suitable for Vehicles and Based on CoSb3 Manufactured Close to Production

Despite the ongoing electrification of vehicle propulsion systems, vehicles with combustion engines will continue to bear the brunt of passenger services worldwide for the next few decades. As a result, the German Aerospace Center Institute of Vehicle Concepts, the Institute of Materials Research and the Institute of Technical Thermodynamics have focused on utilising the exhaust heat of internal combustion engines by means of thermoelectric generators (TEGs). Their primary goal is the development of cost-efficient TEGs with long-term stability and maximised energy yield. In addition to the overall TEG system design, the development of long-term stable, efficient thermoelectric modules (TEMs) for high-temperature applications is a great challenge. This paper presents the results of internal development work and reveals an expedient module design for use in TEGs suitable for vehicles. The TEM requirements identified, which were obtained by means of experiments on the test vehicle and test bench, are described first. Doped semiconductor materials were produced and characterised by production methods capable of being scaled up in order to represent series application. The results in terms of thermoelectric properties (Seebeck coefficient, electrical conductivity and thermal conductivity) were used for the simulative design of a thermoelectric module using a constant-property model and with the aid of FEM calculations. Thermomechanical calculations of material stability were carried out in addition to the TEM’s thermodynamic and thermoelectric design. The film sequence within the module represented a special challenge. Multilayer films facilitated adaptation of the thermal and mechanical properties of plasma-sprayed films. A joint which dispenses with solder additives was also possible using multilayer films. The research resulted in a functionally-optimised module design, which was enhanced for use in motor vehicles using process flexibility and close-to-production manufacturing methods.

Evaluation of Thermoelectric Performance and Durability of Functionalized Skutterudite Legs

Thermoelectric generators are a promising technology for waste heat recovery. As new materials and devices enter a market penetration stage, it is of interest to employ fast and efficient measurement methods to evaluate the long-term stability of thermoelectric materials in combination with metallization and coating (functionalized thermoelectric legs). We have investigated a method for measuring several thermoelectric legs simultaneously. The legs are put under a common temperature gradient, and the electrical characteristics of each leg are measured individually during thermal cycling. Using this method, one can test different types of metallization and coating applied to skutterudite thermoelectric legs and look at the relative changes over time. Postcharacterization of these initial tests with skutterudite legs using a potential Seebeck microprobe and an electron microscope showed that oxidation and interlayer diffusion are the main reasons for the gradual increase in internal resistance and the decrease in open-circuit voltage. Although we only tested skutterudite material in this work, the method is fully capable of testing all kinds of material, metallization, and coating. It is thus a promising method for studying the relationship between failure modes and mechanisms of functionalized thermoelectric legs.