Description:FIELD OF THE INVENTION
This invention relates to Integrated Thermal Energy Harvesting System for Efficient Waste Heat Conversion and Power Generation
BACKGROUND OF THE INVENTION
The problem exists in large-scale heat dissipation which occurs while performing industrial operations and when vehicles operate as well as when electronic devices run. The process of converting waste heat into usable energy faces challenges because current technologies function with limited effectiveness and face economic barriers while operating over restricted temperature conditions. An energy harvesting method should exist that efficiently captures thermal energy because this system would enhance power performance and serve as an environmental protection tool.
EXISTING SOLUTIONS / PRIOR ART/RELATED APPLICATIONS &PATENTS:
Thermoelectric Generators (TEGs):
• Waste heat produces electrical power from the Seebeck effect within thermoelectric generators through the generation of electric voltage from temperature gradients across materials.
• The low efficiency range of TEGs stands at 5-10% while operational effectiveness depends on a robust temperature differential. The utilization of expensive materials coupled with their rarity results in high costs that make their large-scale implementation unfeasible.
Vibration-Based Energy Harvesting Systems:
• The technology harvests energy by converting mechanical vibrations coming from machines or natural environment sources. The energy conversion process from mechanical vibrations to electric power depends mainly on piezoelectric materials.
• These systems operate only with small-scale quantities which work best for low-power requirements. These systems lack suitability in massive waste heat recovery operations because they extract power from mechanical motions instead of thermal fluctuations.
•
Phase Change Materials (PCMs):
• When PCMs transform from solid to liquid states they can absorb and release latent heat entirely. Physical systems embed PCMs to serve as temporary thermal energy storage devices that generate electrical power.
• Heat storage is an effective application of these systems but their conversion process operates slowly and they cannot generate power directly. Most of the time the extraction of energy from Phase Change Materials encounters performance constraints.
Organic Rankine Cycle (ORC) Systems:
• The ORC system functions as a heat engine which converts waste heat into mechanical energy then electrogenerates electricity through organic fluids with low boiling temperatures.
• The limitations of using ORC systems include these requirements for powerful thermal gradient conditions which drives the system costs higher and increases physical size resulting in lower adoption suitability in mobile or smaller-scale applications.
Heat Pipe Systems:
• The passive heat transfer mechanism of heat pipes transfers heat between two areas through liquid-phase transformation processes. Such devices help thermal energy recovery systems achieve better heat transfer efficiency.
• The main drawback of heat pipes is their inability to transform heat into electricity although they function well as heat transport systems. Heat pipes operational within these systems act as elements but power generation usually needs further components such as TEGs to function.
Heat-to-Electricity Conversion via Magnetocaloric and Electrocaloric Effects:
• Emerging technology developments utilize materials that exhibit magnetic or electrical property modification after temperature changes to achieve harvestable waste heat potentials.
• However these technologies exist at the initial levels of research because they lack commercial application capabilities. The implementation of these systems faces problems with operational efficiency together with high materials expenses.
Thermal Photovoltaic Systems (TPVs):
• The energy conversion process through TPVs generates electricity by processing infrared radiation using semiconductor-based photovoltaic cells.
• TPVs function with reduced efficiency compared to conventional photovoltaic cells and struggle to achieve optimal utility from lower operating temperatures of waste heat.
Feature Existing Solutions Proposed TEHS
Efficiency Low to moderate High due to hybrid mechanism
Material Dependency Rare and expensive materials Utilizes advanced, cost-effective alternatives
Scalability Limited Modular and adaptable
Operating Temperature Range Narrow Wide range, covering low to high gradients
Intelligent Control Absent or basic AI-driven dynamic optimization
Cost High Competitive and cost-effective
SUMMARY OF THE INVENTION
This summary is provided to introduce a selection of concepts, in a simplified format, that are further described in the detailed description of the invention.
This summary is neither intended to identify key or essential inventive concepts of the invention and nor is it intended for determining the scope of the invention.
To further clarify advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which is illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail with the accompanying drawings.
A Thermally efficient Thermal Energy Harvesting System (TEHS) serves as the proposed invention to gather heat waste from multiple sources while producing usable electrical power. The system integrates advanced thermoelectric materials with a micro-Organic Rankine Cycle unit which works together with AI-driven optimization for obtaining optimal energy extraction and dynamic operational performance.
BRIEF DESCRIPTION OF THE DRAWINGS
The illustrated embodiments of the subject matter will be understood by reference to the drawings, wherein like parts are designated by like numerals throughout. The following description is intended only by way of example, and simply illustrates certain selected embodiments of devices, systems, and methods that are consistent with the subject matter as claimed herein, wherein:
FIGURE 1: SYSTEM ARCHITECTURE
The figures depict embodiments of the present subject matter for the purposes of illustration only. A person skilled in the art will easily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.
DETAILED DESCRIPTION OF THE INVENTION
The detailed description of various exemplary embodiments of the disclosure is described herein with reference to the accompanying drawings. It should be noted that the embodiments are described herein in such details as to clearly communicate the disclosure. However, the amount of details provided herein is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the present disclosure as defined by the appended claims.
It is also to be understood that various arrangements may be devised that, although not explicitly described or shown herein, embody the principles of the present disclosure. Moreover, all statements herein reciting principles, aspects, and embodiments of the present disclosure, as well as specific examples, are intended to encompass equivalents thereof.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms “a",” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises,” “comprising,” “includes” and/or “including,” when used herein, specify the presence of stated features, integers, steps, operations, elements and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and/or groups thereof.
It should also be noted that in some alternative implementations, the functions/acts noted may occur out of the order noted in the figures. For example, two figures shown in succession may, in fact, be executed concurrently or may sometimes be executed in the reverse order, depending upon the functionality/acts involved.
In addition, the descriptions of "first", "second", “third”, and the like in the present invention are used for the purpose of description only, and are not to be construed as indicating or implying their relative importance or implicitly indicating the number of technical features indicated. Thus, features defining "first" and "second" may include at least one of the features, either explicitly or implicitly.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, e.g., those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
A Thermally efficient Thermal Energy Harvesting System (TEHS) serves as the proposed invention to gather heat waste from multiple sources while producing usable electrical power. The system integrates advanced thermoelectric materials with a micro-Organic Rankine Cycle unit which works together with AI-driven optimization for obtaining optimal energy extraction and dynamic operational performance.
The proposed system incorporates various essential features which will be discussed next.
1. Advanced thermoelectric materials convert high-temperature gradients through the Seebeck effect which produces electricity while achieving high energy conversion efficiency in cases where major temperature differentials exist.
2. The Micro-Organic Rankine Cycle (ORC) Unit serves to optimize energy recovery operations through its capability to transform low-temperature differences into valuable electrical electricity. The micro-ORC unit utilizes low boiling organic fluid materials to perform waste heat recovery from sources with reduced temperature levels.
3. Real-time temperature data enables integrated Artificial Intelligence (AI) systems to automatically manage system operational modes which optimizes energy efficiency output and adjusts to changing waste heat source conditions.
How It Works:
1. Industrial facilities and motor vehicle engines as well as digital electronics have their waste heat collected through thermal recovery methods. The heat exchange system utilizes heat exchangers to achieve proper thermal heat transfer.
2. High temperatures drive the heat to pass through the hybrid conversion module.
The Thermoelectric Generator (TEG) runs best when used in high-temperature gradients to transform thermal energy into electric power directly. The Micro-ORC Unit transforms heat into mechanical energy using organic fluids for electricity generation at lower temperature differences.
3. The power management circuit enables energy conditioning of both TEG and micro-ORC unit electrical output to produce stable power that is ready for usage or storage.
4. Electricity storage takes place in either battery or capacitor systems to achieve continuous power availability and maximize heat waste usage.
5. The performance of the system receives continuous assessment through an AI-based control system which operates at real time. A control system evaluates thermal changes by adjusting both TEG and micro-ORC operations for best energy recovery results. The artificial intelligence system manages energy storage properly by distributing excess energy to essential points.
The system functions in the following consecutive steps:
1. Users obtain waste heat from various heat sources including industrial exhausts and vehicle tailpipes as well as electronics.
2. A heat exchanger enables the system to move captured heat from its source to a destined place effectively.
3. Hybrid Conversion Module (TEG + Micro-ORC):
The Seebeck effect allows TEG to convert high-temperature differences into usable electric power. Micro-ORC Unit utilizes organic fluid to convert lower-temperature thermal differences into electrical power at different temperature levels.
4. The power management circuit operates to manage electrical energy by producing stable output which provides reliable voltage and current for connected devices and storage entities.
5. The refined power receives storage in batteries or capacitors so users can access it anytime based on their needs.
6. The AI-driven control system uses monitored performance data in real-time to achieve optimum energy retrieval and output power optimization. The operational modes of the TEG and micro-ORC unit will be adjusted to match precise temperature gradients and energy requirements at the moment.
The market for waste heat recovery systems demonstrates expected growth since sustainability alongside energy efficiency objectives become essential while energy expenses and environmental restrictions expand. The TEHS stands prepared to become a central player in this developing market sector.
The combination of thermoelectric generation technology and micro-ORC unit defines the TEHS compared to systems based on single technology systems. AI-based dynamic optimization implementation enhances product performance over different operational scenarios which positions the system to be competitive in market sales.
The Thermal Energy Harvesting System (TEHS) serves as a commercially ready technology solution which finds various uses across multiple industries. The technology stands as an exceptionally desirable solution because it recycles waste heat while enhancing energy efficiency while decreasing environment-bound issues. Through its wide industrial applications and environmental benefits and cost-saving potential the TEHS establishes itself as a valuable solution for advancing energy sustainability even as it responds to rising market needs for transformative energy solutions.
NOVELTY:
1. Hybrid Integration of Thermoelectric and Micro-ORC Systems for Enhanced Energy Conversion Efficiency:
The system applies advanced thermoelectric materials with a micro-Organic Rankine Cycle (ORC) platform which allows extraction from multiple temperature gradients. A combined system design between thermoelectric generators (TEGs) and micro-ORC technology enables maximum energy conversion through dual operations at high and low temperature gradients which allows processing various waste heat sources effectively. Such dual energy conversion processes deliver better efficiency than conventional single-conversion technological systems.
2. AI-Driven Optimization for Dynamic Performance Improvement Based on Temperature Variability and Load Requirements:
The system employs artificial intelligence (AI) algorithms to track temperature variations as well as energy utilization demands in real time. An AI system manages the operational modes of thermoelectric and micro-ORC components to guarantee peak performance together with maximum efficiency. Real-time adaptive system control enables maximal conversion efficiency across different operating conditions that include varying temperatures of the heat source and power requirements.
3. Modular and Scalable Design:
The thermal energy harvesting system incorporates features that ensure modular construction alongside expansion capabilities. This system can function in numerous deployment scenarios because its adaptable design works both on electronic devices and industrial applications. The system design incorporates modular elements which yield customizable operations that help users tailor their energy requirements across industrial environments and multiple applications dimensions. The system displays adjustable capabilities which lead to efficient waste heat recovery throughout various integrated applications including cars, factories and consumer electronics interfaces.
ADVANTAGES OF THE INVENTION
• This system achieves maximum efficiency by uniting thermoelectric materials with micro-ORC technology so it can extract waste heat from diverse temperature ranges effectively.
• The system demonstrates two key advantages through its size adaptability since it effectively operates across small and large application scales including industrial heat recovery systems and automotive energy capture systems and electronic thermal energy management systems.
• The system uses AI-based optimization to reach peak performance through environmental-aware control adjustments. The system establishes sustainability through electricity generation from wasted heat which simultaneously lowers power consumption and decreases environmental footprint.
• The Thermal Energy Harvesting System (TEHS) features a flexible and affordable approach to waste heat recovery by transforming this energy into usable power and performing advanced control-based energy optimization systems.
• The Thermal Energy Harvesting System (TEHS) proposal can apply toward multiple sectors of industry to address wasted energy while promoting energy efficiency and sustainability.
Industrial Waste Heat Recovery:
• The manufacturing sector together with chemical producers and metal refiners create large volumes of waste heat which typically exposes to environmental discharge. Such recovered industrial waste heat can be used by TEHS units to generate electricity thus replacing conventional power supplies while decreasing operational expenditures.
• The use of the technology enables industries to cut their dependence on external energy supplies thus establishing enhanced energy self-sufficiency together with sustainability. The installation of TEHS helps organizations fulfill government criteria regarding energy efficiency improvements and emissions mitigation objectives.
Automotive Exhaust Heat Utilization:
• The TEHS finds its application in vehicles since internal combustion engine vehicles produce substantial heat when their exhaust gases escape. The TEHS extracts waste heat from sources and utilizes this energy to generate electricity that either runs electrical systems installed in the vehicle or stores power within battery cells for later usage.
• A system built with TEHS enables fuel efficiency improvements because it eliminates dependency on extra energy output from the engine. The system proves valuable for electric and hybrid vehicles because it offers supplementary power storage to minimize environmental emissions.
Energy Recovery in Electronic Devices:
• Electronic devices consisting of computers smartphones and servers create heat during their operational period. Waste heat recovery through the TEHS enables energy-efficient improvements or forward utilization of stored energy within these devices.
• The usage of TEHSs decreases both power usage and thermal problems which results in longer-lasting device operations. Reducing electricity costs occurs when businesses use high-performance electronic equipment because of this application.
Renewable Energy Systems:
• The TEHS finds its application alongside solar or wind energy by extracting waste heat produced by solar panel operations or wind turbine operations. The collected waste energy becomes available for generating supplementary power.
• The TEHS system raises renewable system output levels to boost their efficiency and extends their capacity to produce consistent and dependable renewable energy.
• Several environmental advantages exist within the proposed TEHS because it stops useless energy from going to waste while simultaneously enhancing energy conservation methods.
Reduces Greenhouse Gas Emissions:
• The system functions as an application to recover wasted heat to generate usable power which in turn decreases the need for fossil-fuel-driven electricity generation. The decrease in energy consumption because of this system results in both less air pollution and reduced carbon emissions throughout industrial operations as well as automotive operations and electronic equipment.
• The system helps global climate change mitigation through its role as a different energy source alternative to traditional carbon dioxide and harmful gas-emitting energy systems.
Improves Overall Energy Efficiency:
• The ability to extract waste heat from various sources enhances system and process efficiency as well as vehicle operation efficiency. Such systems recover and reuse heat that would normally be wasted in order to optimize the energy output produced from any given energy source.
• The enhanced efficiency of energy usage decreases the need for outside energy resources which results in reduced expenses and lessening of environmental damages due to energy production specifically in high-energy-consuming industries.
Commercial Viability:
• The Thermal Energy Harvesting System has substantial commercial value because it applies across diverse fields while providing sustained cost reductions through its operations.
• The system offers commercial potential through sales to Industrial, Vehicle and Electronics industries.
• The system offers marketing potential to multiple industries which consist of manufacturing together with automotive and energy and electronics production. The waste heat recovery system finds its best use in industrial facilities such as power stations and chemical manufacturing units and metal processing operations while automobile companies can enhance their fuel economy. The energy management capabilities of this technology allow electronics producers to integrate it into their products.
The TEHS enables business organizations to minimize their energy expenses along with fulfilling stringent energy conservation laws and environmental standards.

 
, Claims:1. An integrated thermal energy harvesting system, comprising:
a heat exchanger adapted to collect waste heat from at least one source selected from the group consisting of industrial exhausts, vehicle engines, and electronic devices;
a hybrid conversion module comprising a thermoelectric generator (TEG) and a micro-organic Rankine cycle (micro-ORC) unit, wherein the TEG is configured to convert high-temperature heat gradients into electrical energy and the micro-ORC unit is configured to convert lower-temperature heat differences using organic fluid into mechanical energy for further conversion to electrical power;
a power management circuit electrically connected to both the TEG and the micro-ORC unit, said circuit being adapted to stabilize and condition the electrical output;
an energy storage unit comprising at least one of a battery or a capacitor, operatively connected to the power management circuit; and
an artificial intelligence (AI)-based control system configured to monitor thermal performance in real time and dynamically adjust operations of the TEG and the micro-ORC unit based on current temperature gradients and energy requirements for optimized energy harvesting and storage.

2. The system as claimed in claim 1, wherein the heat exchanger is adapted to transfer heat efficiently from a waste heat source to the hybrid conversion module using conductive or convective thermal transfer mechanisms.
3. The system as claimed in claim 1, wherein the AI-based control system is further adapted to manage energy storage by monitoring power output and distributing excess energy to connected essential loads or storage media.
4. The system as claimed in claim 1, wherein the power management circuit is configured to regulate voltage and current to produce a stable and usable power supply for external devices or internal storage.
5. The system as claimed in claim 1, wherein the hybrid conversion module utilizes the Seebeck effect in the TEG for direct thermal-to-electric conversion and an organic working fluid in the micro-ORC unit to enable efficient low-grade heat conversion.