Claims:We Claim:

1. An exhaust heat thermoelectric generator system (100) for a vehicle, the system (100) comprising:
at least one thermoelectric generator (1) defined with a first conduction side (1a) and a second conduction side (1b);
at least one exhaust tube (2) defined with an exhaust inlet (2a) and an exhaust outlet (2b), wherein the at least one exhaust tube (2) is thermally connected to the first conduction side (1a) of the at least one thermoelectric generator (1);
at least one coolant circuit (3) defined with a coolant inlet (3a) and a coolant outlet (3b), wherein the at least one coolant circuit (3) is thermally connected to the second conduction side (1b) of the at least one thermoelectric generator (1),
wherein, exhaust gas in the at least one exhaust tube (2) heats the first conduction side (1a) and coolant in the at least one coolant circuit (3) cools the second conduction side (1b) such that,
a temperature gradient between the first conduction side (1a) and the second conduction side (1b) generates electricity from the thermoelectric generator (1).

2. The system (100) as claimed in claim 1 wherein, the at least one thermoelectric generator (1) is sandwiched between the at least one exhaust tube (2) and the at least one coolant circuit (3) and, each of the at least one thermoelectric generator (1) is stacked alternatively after the at least one exhaust tube (2) and the at least one coolant circuit (3).

3. The system (100) as claimed in claim 1 comprises an exhaust inlet casing (4) defined with at least one exhaust inlet slot (4a) connected to the exhaust inlet (2a) of the at least one exhaust tube (2).

4. The system (100) as claimed in claim 1 comprises an exhaust outlet casing (5) defined with at least one second slot (5a) connected to the exhaust outlet (2b) of the at least one exhaust tube (2).

5. The system (100) as claimed in claim 1 comprises an inlet coolant tube (6) fluidically connected to the coolant inlet (3a) of each of the at least one coolant circuit (3) and a outlet coolant tube (7) is fluidically connected to the coolant outlet (3b) of each of the at least one coolant circuit (3) to facilitate coolant flow in and out of the coolant circuit (3).

6. The system (100) as claimed in claim 1 comprises, a flexible connector (8) for interconnecting the inlet coolant tube (6) with the coolant inlet (3a) of the at least one coolant circuit (3) and the outlet coolant tube (7) with the coolant outlet (3b) of the at least one coolant circuit (3).

7. The system (100) as claimed in claim 1 wherein, the at least one coolant circuit (3) comprises:
a heat sink (9) sandwiched between a first coolant tube (10) and a second coolant tube (11),
wherein, the heat sink (9) dissipates heat from the coolant flowing through the first coolant tube (10) and the second coolant tube (11).

8. The system (100) as claimed in claim 1 wherein, the at least one exhaust tube (2) comprises:
a pair of spaced apart frames (12a and 12b);
a plurality of ribs (13) interconnecting the pair of spaced apart frames (12a and 12b) and positioned at pre-determined distance between the exhaust inlet (2a) and the exhaust outlet (2b);
at least one enclosure (18) housed on the pair of frames (12a and 12b) and enclosing the pair of frames (12a and 12b) thereby defining a channel for the flow of exhaust gases.

9. The system (100) as claimed in claim 8 wherein, thickness and width of the plurality of ribs (13) gradually decreases from the exhaust inlet (2a) side to the exhaust outlet (2b) side for uniform distribution of heat throughout the exhaust tube (2).

10. The system (100) as claimed in claim 8 comprises, a plurality of first ribs (13a) configured to extend between the pair of frames (12) along a top end (12x) of the pair of frames (12) and a plurality of second ribs (13b) configured to extend between the pair of frames (12) along a bottom end (12y) of the pair of frames (12) on the exhaust tube (2).

11. The system (100) as claimed in claim 10 wherein, the plurality of first ribs (13a) and the plurality of second ribs (13b) are configured alternatively between the pair of frames (12) to support at least one enclosure (18).

12. The system (100) as claimed in claim 1 comprising, an auxiliary heat exchanger connected to the inlet coolant tube (6) and the outlet coolant tube (7), wherein the auxiliary heat exchanger (15) receives hot coolant and reduces the temperature of coolant.

13. The system (100) as claimed in claim 1 comprises, a duct (16) connected to the exhaust inlet casing (4) and the exhaust outlet casing (5) wherein, the duct (16) is defined with a bypass valve for bypassing the exhaust gases when the temperature of the exhaust gases increases beyond a pre-determined threshold.

14. The system (100) as claimed in claim 1 comprises, a control unit for switching the connection of output terminals of each of the thermoelectric generator (1) from a series connection to a parallel connection and vice versa based on predetermined parameters for harnessing optimal power output from the thermoelectric generators (1).

15. The system (100) as claimed in claim 1 wherein, each combination of the thermoelectric generator (1) and the coolant circuit (3) or each combination of the thermoelectric generator (1), the exhaust tube (2) and the coolant tube (3) may be secured together by fasteners (14) on the support structures (23) to apply individual clamping force onto each of the combination of the thermoelectric generator (1), the exhaust tube (2) and the coolant tube (3).

16. A method of recovering energy from exhaust heat from a vehicle, the method comprising:
circulating exhaust gas through at least one exhaust tube (2) defined with an exhaust inlet (2a) and an exhaust outlet (2b) wherein, the at least one exhaust tube (2) is thermally connected to the first conduction side (1a) of the at least one thermoelectric generator (1);
heating a first conduction side (1a) of at least one thermoelectric generator (1);
circulating coolant through at least one coolant circuit (3) defined with a coolant inlet (3a) and a coolant outlet (3b) wherein, the at least one coolant circuit (3) is thermally connected to the second conduction side (1b) of the at least one thermoelectric generator (1);
cooling a second conduction side (1b) of at least one thermoelectric generator (1);
harnessing electricity generated by the thermoelectric generator (1) due to a temperature gradient between the first conduction side (1a) and the second conduction side (1b).

17. The method as claimed in claim 17 comprises, dissipating heat from the coolant passing through the coolant circuit (3) by circulating air through a heat sink (9) sandwiched between a first coolant tube (10) and a second coolant tube (11).

18. The method as claimed in claim 17 comprises, facilitating the flow of exhaust gases through the at least one exhaust tube (2) by at least one enclosure (18) housed on a top end (12x) and a bottom end (12y) of a pair of frames (12a and 12b), and enclosing the pair of frames (12a and 12b) thereby defining a channel for the flow of exhaust gases.

19. The method as claimed in claim 17comprises, reducing the temperature of coolant in the coolant circuit (3) by configuring an auxiliary heat exchanger connected to an inlet coolant tube (6) and an outlet coolant tube (7) wherein, the coolant flow between the auxiliary heat exchanger (15) and the at least one coolant circuit (3) is by siphon circulation and the coolant is air cooled.

20. The method as claimed in claim 17comprises, bypassing the exhaust gases when the temperature of the exhaust gases increases beyond a pre-determined threshold through a duct (16) connected to an exhaust inlet casing (4) and an exhaust outlet casing (5).

Dated 17th day of September 2021

GOPINATH A S
IN/PA 1852
OF K&S PARTNERS
AGENT FOR THE APPLICANT
, Description:FORM 2
THE PATENTS ACT 1970
[39 OF 1970]
&
The Patents Rules, 2003

COMPLETE SPECIFICATION
[See section 10 and rule 13]

TITLE: “AN EXHAUST HEAT THERMOELECTRIC GENERATOR SYSTEM FOR A VEHICLE AND A METHOD THEREOF”

Name and address of the Applicant:
TATA MOTORS LIMITED, an Indian company having its registered office at Bombay House, 24 Homi Mody Street, Hutatma Chowk, Mumbai 400 001, Maharashtra, INDIA.

Nationality: INDIAN

The following specification particularly describes the invention and the manner in which it is to be performed.
TECHNICAL FIELD

Present disclosure generally relates to the field of automobiles. Particularly but not exclusively, the present disclosure relates to an exhaust heat recovery system for vehicles. Further, embodiments of the present disclosure, discloses a system and a method for generating electricity by harnessing heat from the exhaust gases emitted by internal combustion engine vehicles.

BACKGROUND OF THE INVENTION

Internal combustion engines involve combustion of a fuel in order to generate power for movement of the vehicle. Combustion of fuel occurs with an oxidizer in a combustion chamber. This combustion converts the chemical energy of fuel into usable energy. Generally, only a small portion of the energy is released in combustion of the fuel and is converted by the internal combustion engine into desirable/usable energy. However, the bulk of the energy losses in the internal combustion engines is through exhaust gases. Particularly, the energy losses in internal combustion engines are through the heat from the exhaust gases. This loss of energy through heat from the exhaust gases is about 35 percent to 45 percent of the energy generated through combustion of the fuel and the oxidizer in the internal combustion engine.

The existing methods of recovering energy from the exhaust gases are inefficient and extremely complex. Systems such as Rankine cycle systems are used to vaporize water using a steam generator located in the exhaust pipe. The fluid is turned into steam due to heat by the exhaust gases and the steam then drives the expander of the Rankine engine. The expander may be directly tied to the crankshaft of the thermal engine or linked to an alternator to generate electricity. Generally, the expander is a turbine and is run by the steam generated from the exhaust gases. However, the above-mentioned system used for recovering the heat from exhaust gases is extremely complex. Housing the above-mentioned system in the vehicle also becomes difficult due to the space constraints in the vehicle and due to the large size of the components in the Rankine system. Further, the size of the turbine used in the expander is often severely limited due to space constraints. Consequently. The operational efficiency of the turbine reduces drastically due to the smaller size of the turbine and lower surface area for the impact of the steam onto the turbine blades.

Further, thermoelectric generators have also been used to convert the exhaust heat energy from the internal combustion engine into usable current. However, configuring such thermoelectric generators harnesses the heat energy from the exhaust gases is extremely complex and multiple thermoelectric generators may not be used due to constructional and configurational limitations.

The present disclosure is directed to overcome one or more limitations stated above, or any other limitation associated with the prior arts.

SUMMARY OF THE DISCLOSURE

One or more shortcomings of the conventional system or method are overcome, and additional advantages are provided through the provision of the method as claimed in the present disclosure.

Additional features and advantages are realized through the techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered a part of the claimed disclosure.

In one non-limiting embodiment of the disclosure, an exhaust heat thermoelectric generator system for a vehicle is disclosed. The system includes at least one thermoelectric generator defined with a first conduction side and a second conduction side. At least one exhaust tube is defined with an exhaust inlet and an exhaust outlet where the at least one exhaust tube is thermally connected to the first conduction side of the at least one thermoelectric generator. Further, at least one coolant circuit is defined with a coolant inlet and a coolant outlet, where the at least one coolant circuit is thermally connected to the second conduction side of the at least one thermoelectric generator. Further, the exhaust gas in the at least one exhaust tube heats the first conduction side and coolant in the at least one coolant circuit cools the second conduction side such that a temperature gradient between the first conduction side and the second side generates electricity from the thermoelectric generator.

In an embodiment of the disclosure, the at least one thermoelectric generator is sandwiched between the at least one exhaust tube and the at least one coolant circuit and, each of the at least one thermoelectric generator is stacked alternatively after the at least one exhaust tube and the at least one coolant (Or equivalent heat dissipation side) circuit.

In an embodiment of the disclosure, an exhaust inlet distributor is defined with at least one first slot connected to the exhaust inlet of the at least one exhaust tube.

In an embodiment of the disclosure, an exhaust outlet distributor is defined with at least one second slot connected to the exhaust outlet of the at least one exhaust tube.

In an embodiment of the disclosure, an inlet coolant tube is fluidically connected to the coolant inlet of each of the at least one coolant circuit (Or equivalent Finned surface/heat pipe/ heat dissipation circuit) and an outlet coolant tube is fluidically connected to the coolant outlet of each of the at least one coolant circuit to facilitate coolant flow in and out of the coolant circuit.

In an embodiment of the disclosure, a flexible connector is provided for interconnecting the coolant inlet tube with the coolant inlet of the at least one coolant circuit and the coolant outlet tube with the coolant outlet of the at least one coolant circuit.

In an embodiment of the disclosure, the at least one coolant circuit includes a heat sink between a first coolant tube and a second coolant tube. The heat sink dissipates heat from the coolant flowing through the first coolant tube and the second coolant tube.

In an embodiment of the disclosure, the at least one exhaust tube includes a pair of spaced apart frames, a plurality of ribs interconnecting the pair of spaced apart frames (and housed in the slots) and positioned at pre-determined distance between the exhaust inlet and the exhaust outlet. At least one enclosure is housed on the pair of frames, enclosing the pair of frames of and thereby defining an enclosed channel for the flow of exhaust gases.

In an embodiment of the disclosure, the thickness and width and fin count of the plurality of ribs/fins gradually decreases from the exhaust inlet side to the exhaust outlet side for uniform distribution of heat throughout the exhaust tube.

In an embodiment of the disclosure, a plurality of first ribs is configured to extend between the pair of frames along a top end of the pair of frames and a plurality of second ribs is configured to extend between the pair of frames along a bottom end of the pair of frames on the exhaust tube alternatively.

In an embodiment of the disclosure, the plurality of first ribs and the plurality of second ribs are configured alternatively between the pair of frames to support at least one enclosure.

In an embodiment of the disclosure, an auxiliary heat exchanger is connected to the coolant inlet tube and the coolant outlet tube, wherein the auxiliary heat exchanger receives hot coolant and reduces the temperature of coolant.

In an embodiment of the disclosure, a duct is connected to the exhaust inlet distributor and the exhaust outlet distributor where, the duct is defined with a bypass valve for bypassing the exhaust gases when the temperature of the exhaust gases increases beyond a pre-determined threshold.

In an embodiment of the disclosure, the system may include a control unit for switching the connection of output terminals of each of the thermoelectric generator from a series connection to a parallel connection and vice versa based on predetermined parameters for harnessing optimal power output from the thermoelectric generators.

In an embodiment of the disclosure, each combination of the thermoelectric generator and the coolant circuit or each combination of the thermoelectric generator, the exhaust tube and the coolant tube may be secured together by fasteners on the support structures to apply individual clamping force onto each of the combination of the thermoelectric generator, the exhaust tube and the coolant tube.

In one non-limiting embodiment of the disclosure, a method of recovering energy from exhaust heat from a vehicle is disclosed. The method includes aspects of circulating exhaust gas through at least one exhaust tube defined with an exhaust inlet and an exhaust outlet. The at least one exhaust tube is thermally connected to the first conduction side of the at least one thermoelectric generator. Further, a first conduction side of at least one thermoelectric generator is heated. The method also includes aspects of circulating coolant through at least one coolant circuit defined with a coolant inlet and a coolant outlet where, the at least one coolant circuit is thermally connected to the second conduction side of the at least one thermoelectric generator. A second conduction side of at least one thermoelectric generator is cooled. The electricity generated by the thermoelectric generator due to a temperature gradient between the first conduction side and the second conduction side is harnessed.

The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.

BRIEF DESCRIPTION OF THE ACCOMPANYING FIGURES

The novel features and characteristic of the disclosure are set forth in the appended claims. The disclosure itself, however, as well as a preferred mode of use, further objectives, and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying figures including but not limited to the embodiments described with the accompanying figures. One or more embodiments are now described, by way of example only, with reference to the accompanying figures wherein like reference numerals represent like elements and in which:

Fig. 1 illustrates a perspective view of an exhaust heat thermoelectric generator system, in accordance with an embodiment of the present disclosure.

Fig. 2 illustrates an exploded perspective view of the exhaust heat thermoelectric generator system, in accordance with an embodiment of the present disclosure.

Fig. 3 illustrates a magnified perspective view of section “A” of the Fig. 2.

Fig. 4 illustrates an exploded perspective view of an exhaust inlet and outlet distributor, in accordance with an embodiment of the present disclosure.

Fig. 5 illustrates a perspective view of a coolant circuit in the exhaust heat thermoelectric generator system, in accordance with an embodiment of the present disclosure.

Fig. 6 illustrates a perspective view of the exhaust tube with the enclosure in the exhaust heat thermoelectric generator system, in accordance with an embodiment of the present disclosure.

Fig. 7 illustrates a perspective view of the exhaust tube without the enclosure in the exhaust heat thermoelectric generator system, in accordance with an embodiment of the present disclosure.

Fig. 8 illustrates an exploded perspective view of the exhaust tube in the exhaust heat thermoelectric generator system, in accordance with an embodiment of the present disclosure.

Fig. 9 is a side view of a plurality of fins in the exhaust tube in the exhaust heat thermoelectric generator system, in accordance with an embodiment of the present disclosure.

Fig. 10 is a simulated image of the exhaust tube illustrating the surface temperature distribution throughout the exhaust tube, in accordance with an embodiment of the present disclosure.

Fig. 11 illustrates an exploded perspective view of a stack of the exhaust tubes, the thermoelectric generators, and the coolant circuits in the exhaust heat thermoelectric generator system, in accordance with an embodiment of the present disclosure.

Fig. 12 illustrates an assembled perspective view of the stack of the exhaust tubes, the thermoelectric generators, and the coolant circuits in the exhaust heat thermoelectric generator system, in accordance with an embodiment of the present disclosure.

Fig. 13 illustrates an exploded perspective view of the exhaust heat thermoelectric generator system with an auxiliary heat exchanger, in accordance with an embodiment of the present disclosure.

The figure depicts embodiments of the disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the exhaust heat thermoelectric generator system for the vehicle for the vehicle without departing from the principles of the disclosure described herein.

DETAILED DESCRIPTION

The foregoing has broadly outlined the features and technical advantages of the present disclosure in order that the description of the disclosure that follows may be better understood. Additional features and advantages of the disclosure will be described hereinafter which form the subject of the disclosure. It should be appreciated by those skilled in the art that the conception and specific embodiments disclosed may be readily utilized as a basis for modifying or designing other system for carrying out the same purposes of the present disclosure. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the disclosure. The novel features which are believed to be characteristic of the disclosure, as to its organization, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present disclosure.

In the present document, the word "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any embodiment or implementation of the present subject matter described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments.

While the disclosure is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and will be described below. It should be understood, however that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternative falling within the scope of the disclosure.

The terms “comprises”, “comprising”, or any other variations thereof, are intended to cover a non-exclusive inclusions, such that a system that comprises a list of components does not include only those components but may include other components not expressly listed or inherent to such mechanism. In other words, one or more elements in the device or mechanism proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the mechanism.

Embodiments of the present disclosure discloses an exhaust heat thermoelectric generator system for a vehicle. Existing methods of recovering energy from the exhaust gases are inefficient and extremely complex. Systems such as Rankine cycle systems are used to vaporize water using a steam generator located in the exhaust pipe. The fluid is turned into steam due to heating by exhaust gases and the steam then drives the expander of the Rankine engine. The expander may be directly tied to the crankshaft of the thermal engine or linked to an alternator to generate electricity. Housing the above-mentioned system in the vehicle becomes difficult due to the space constraints in the vehicle and due to the large size of the components in the Rankine system. Further, the size of the turbine used in the expander is often severely limited due to space constraints. Consequently. The operational efficiency of the turbine reduces drastically due to the smaller size of the turbine and lower surface area for the impact of the steam onto the turbine blades.

Accordingly, the present disclosure discloses the exhaust heat thermoelectric generator system for a vehicle. The system includes at least one thermoelectric generator defined with a first conduction side and a second conduction side. At least one exhaust tube defined with an exhaust inlet and an exhaust outlet is provided where the at least one exhaust tube is thermally connected to the first conduction side of the at least one thermoelectric generator. Further, at least one coolant circuit is defined with a coolant inlet and a coolant outlet, where the at least one coolant circuit is thermally connected to the second conduction side of the at least one thermoelectric generator. A coolant inlet tube is fluidically connected to the coolant inlet of each of the at least one coolant circuit and a coolant outlet tube is fluidically connected to the coolant outlet of each of the at least one coolant circuit to facilitate coolant flow in and out of the coolant circuit. Further, a flexible connector is provided for interconnecting the coolant inlet tube with the coolant inlet of the at least one coolant circuit and the coolant outlet tube with the coolant outlet of the at least one coolant circuit The at least one coolant circuit includes a heat sink/fins sandwiched between a first coolant tube and a second coolant tube. The heat sink dissipates heat from the coolant flowing through the first coolant tube and the second coolant tube. The at least one exhaust tube includes a pair of spaced apart frames, a plurality of ribs/fins interconnecting the pair of spaced apart frames and positioned at pre-determined distance and orientation between the exhaust inlet and the exhaust outlet. At least one enclosure is housed on the pair of frames, enclosing the pair of frames thereby defining a channel for the flow of exhaust gases. The at least one thermoelectric generator is sandwiched between the at least one exhaust tube and the at least one coolant circuit and, each of the at least one thermoelectric generator is stacked after the at least one exhaust tube or the at least one coolant circuit. Further, the exhaust gas in the at least one exhaust tube heats the first conduction side and coolant in the at least one coolant circuit cools the second conduction side such that a temperature gradient between the first conduction side and the second side generates electricity from the thermoelectric generator.

The following paragraphs describe the present disclosure with reference to Figs. 1 to 12.

Fig. 1 illustrates an assembled perspective view of an exhaust heat thermoelectric generator system (100) and Fig. 2 illustrates an exploded perspective view of the exhaust heat thermoelectric generator system (100) [herein after referred to as “the system”]. The system (100) includes an exhaust inlet distributor (4) and an exhaust outlet distributor (5) for guiding exhaust gases from an internal combustion engine [not shown in figure] in a pre-defined path. Usually, the exhaust gases generated by the internal combustion engine is exhausted through the exhaust manifold. The exhaust gases from the internal combustion engine are at very high temperatures and these gases may initially be directed to the exhaust inlet distributor (4). The system (100) also includes at least one exhaust tube (2) [hereinafter referred to as “the exhaust tube”] and at least one coolant circuit (3) [hereinafter referred to as “the coolant circuit”] which are stacked one above the other in an alternate configuration, wherein a defined space is provided to accommodate at least one thermoelectric generator (1). In an embodiment, various other configurations of the exhaust tube (2) and the coolant circuit (3) are possible, however the same shall not be considered as limitation. The at least one thermoelectric generator (1) [hereinafter referred to as “the thermoelectric generator”] is sandwiched between the exhaust tube (2) and the coolant circuit (3). In a preferred embodiment, multiple thermoelectric generators (1) may be stacked one above the other where, each of the multiple thermoelectric generators (1) are sandwiched between the exhaust tube (2) and the coolant circuit (3). The exhaust tubes (2) may be connected to the exhaust inlet distributor (4) at one end and the other end of the exhaust tube (2) may be connected to the exhaust outlet distributor (5). The exhaust gases from the internal combustion engine may be directed into the exhaust tube (2) through the exhaust inlet distributor (4). Referring to Fig. 9, the thermoelectric generators (1) may be defined by a first conduction side (1a) and a second conduction side (1b). The exhaust tubes (2) may be thermally connected or positioned on the first conduction side (1a) of the thermoelectric generators (1) whereas the coolant circuit may be thermally connected or positioned on the second conduction side (1b) of the thermoelectric generators (1). Referring to Fig. 2, the system (100) includes an inlet coolant tube (6) and an outlet coolant tube (7). The inlet coolant tube (6) and the outlet coolant tube (7) may be connected to the coolant circuit (3) by a plurality of flexible connectors (8) [hereinafter referred to as “the flexible connectors”]. The flexible connectors (8) may be of any material including but not limited to rubber, polyurethane, EPDM, braided hose etc. The flexible connectors (8) may be provided with a plurality of washers [not shown in figures] along the connecting regions of the inlet coolant tube (6) and the outlet coolant tube (7) to prevent leakage of the coolant. The plurality of washers may also be provided along the connecting regions of the coolant circuit (3), the inlet coolant tube (6) and the outlet coolant tube (7). The system (100) also includes a duct (16) connected to the exhaust inlet distributor (4) and the exhaust outlet distributor (5). The duct (16) is configured with a bypass valve (16a) for bypassing the exhaust gases when the temperature of the exhaust gases increases beyond a pre-determined threshold. The duct (16) may herein be configured to extend along a central axis (A-A) of the system (100) and the same must not be construed as a limitation. The duct (16) may be connected to an inlet and an outlet along a central region of the exhaust inlet distributor (4) and the exhaust outlet distributor (5) respectively. Further, the duct (16) may also include a sensor [not shown in figure] for measuring the temperature of the exhaust gases in the system (100). The sensor may be connected to a control unit to determine temperature of the overall system (100). The control unit may also receive signals from the sensor corresponding to the temperature of the exhaust gases in real time. The control unit may further compare the temperature of the exhaust gases with a pre-determined threshold temperature. Further, if the determined temperature of the exhaust gases in the system (100) exceeds the pre-determined threshold temperature, the control unit may engage an actuator connected to the bypass valve (16a). The bypass valve (16a) may subsequently be opened for the direct flow of exhaust gases from the exhaust inlet distributor (4) to the exhaust outlet distributor (5). Direct bypass of exhaust gases out of the system (100) may prevent the thermoelectric generators (1) from being damaged by exposure to high temperatures.

In an embodiment, the thermoelectric generator (1) is a Seebeck effect-based energy harvesting module and the same must not be considered as a limitation as any known modules which generate electricity based on temperature gradient may be used.

In an embodiment, the thermoelectric generator (1) is manufactured specifically for converting low heat sources directly into electricity. In an embodiment, the thermoelectric generator (1) is a Bismuth telluride module doped specifically for low temperature DT (delta temperature) efficiently converting low DT into electricity. The module is constructed with high thermal conductivity graphite sheets on both sides of the ceramic plates, with high element legs.

Fig. 4 illustrates an exploded perspective view of an exhaust inlet distributor (4) and the exhaust outlet distributor (5). The exhaust inlet distributor (4) and the exhaust outlet distributor (5) may be defined with a plurality of exhaust inlet slots (4a) and exhaust outlet slots (5a) respectively. The exhaust inlet slots (4a) may be connected to an exhaust inlet (2a) of the exhaust tube (2) and the exhaust outlet slots (5a) may be connected to an exhaust outlet (2b) of the exhaust tube (2) [seen from Fig. 6]. Further, the exhaust inlet distributor (4) and the exhaust outlet distributor (5) may also be defined with a provision for accommodating the duct (16). In an embodiment, the exhaust inlet distributor (4) and the exhaust outlet distributor (5) may be a single unit including multiple plates that are connected by any known means in the art including but not limited to welding, brazing or through fasteners (14 and 14a).

Fig. 5 illustrates a perspective view of the coolant circuit (3). Referring to Fig. 5 and Fig. 3, the coolant circuit (3) includes a heat sink (9) that is sandwiched between a first coolant tube (10) and a second coolant tube (11). The first coolant tube (10) and the second coolant tube (11) may be connected to a unified coolant inlet (3a) and a coolant outlet (3b) respectively. More particularly with a prescribed height difference between the conduction face of the coolant tube and the common unified inlet and outlet. Further, the coolant inlet (3a) of the coolant circuit (3) may be connected to the inlet coolant tube (6) and the coolant outlet (3b) may be connected to the outlet coolant tube (7). The coolant may flow through the inlet coolant tube (6) into the coolant inlet (3a) and the coolant may flow out of the coolant circuit (3) through the coolant outlet (3b) and the outlet coolant tube (7). The heat sink (9) configured between two coolant tube aids in dissipates heat from the coolant flowing through the first coolant tube (10) and the second coolant tube (11) and contributes towards the further reduction of temperature of the coolant. The system (100) may be positioned in the vehicle such that air directly passes through the heat sink (9) in the system (100) and thereby allows for heat dissipation from the coolant in the first coolant tube (10) and the second coolant tube (11). The inlet and the outlet coolant tube (10 and 11) may be made of any high conductivity material including but not limited to Aluminum, copper etc. The coolant circuit is stacked in the system (100) such that the second conduction side (1b) of the thermoelectric generator (1) remains in contact with the first coolant tube (10) or the second coolant tube (11). The coolant circuit (3) may also include a plurality of extensions [not shown in figures] for enabling the stacking of the coolant circuit (3).

In an embodiment, a fan or flow generating machine may be positioned in front of the system (100) for forcing the ram air towards the heat sink (9) of the system (100). In an embodiment, the coolant circuit (3) may be a set of fins, or the heat sink (9) where, ram air may be directed on to the fins. The fins may dissipate heat from the second conduction side (1b) of the thermoelectric generator (1).

In an embodiment, fins may be connected between the first coolant tube (10) and the second coolant tube (11). The fins may be connected to the first coolant tube (10) and the second coolant tube (11) by any known means in the art including but not limited to brazing, welding, fasteners, rivets etc.

Fig. 6 illustrates a perspective view of the exhaust tube (2) with an enclosure (18) and Fig. 7 illustrates a perspective view of the exhaust tube (2) without the enclosure (18). Fig. 8 illustrates an exploded perspective view of the exhaust tube (2). The exhaust tube (2) may include a pair of frames (12a and 12b) that are spaced apart from each other by a pre-determined distance. The pair of frames (12a and 12b) may be defined on a top end (12x) and a bottom end (12y). The pair of frames (12a and 12b) may be connected to the exhaust inlet (2a) at one end and the exhaust outlet (2b) at the other end. The exhaust inlet (2a) may be connected to the exhaust inlet slots (4a) defined to the exhaust inlet distributor (4). The exhaust outlet (2b) may be connected to the exhaust outlet slots (4b) defined to the exhaust outlet distributor (5). The pair of frames (12a and 12b) are configured with a plurality of ribs (13) and the plurality of ribs (13) interconnects the pair of spaced apart frames (12a and 12b) and are positioned at pre-determined distance between the exhaust inlet (2a) and the exhaust outlet (2b). The plurality of ribs (13) may herein be defined as a plurality of first ribs (13a) [hereinafter referred to as “the first ribs”] and a plurality of second set of ribs (13b) [hereinafter referred to as “the second ribs”]. The first ribs (13a) may be configured to extend between the pair of frames (12) along the top end (12x) of the pair of frames (12) and the second ribs (13b) may be configured to extend between the pair of frames (12) along the bottom end (12y) of the pair of frames (12). Further each of the first ribs (13a) and the second ribs (13b) are configured alternatively between the exhaust inlet (2a) and the exhaust outlet (2b). At least one enclosure (18) is housed on the pair of frames (12a and 12b) to form the exhaust tube (2). The at least one enclosure (18) enclosing the pair of frames (12a and 12b) thereby defines a channel for the flow of exhaust gases and in turn forms the exhaust tube (2). The at least one enclosure (18) may be fixedly housed on the top end (12x) and the bottom end (12y) of the pair of frames (12) may mean of a plurality of fasteners (14 and 14a). The pair of frames (12) may be defined with provisions for accommodating the fasteners (12 and 12a) and securing the at least one enclosure (18). The exhaust tube (2) may be made of any material which offers low thermal co-efficient of expansion and the exhaust tube (2) is assembled without any hot working process such as welding or brazing. The weld joints when subjected to high stresses during the flow of exhaust gases often tend to fail. Consequently, the complete exhaust tube (2) is assembled with fasteners (14 and 14a) without any hot working process.

In an embodiment, the pair of enclosures (18) may be connected to the top end (12x) and the bottom end (12y) of the pair of frames (12) by a plurality of bolts and nuts. The dimensions or the height of the bolt head may be lesser than the overall thickness of the thermoelectric generator (1). Consequently, multiple stacks of thermoelectric generators (1) and exhaust tubes (2) may be accommodated.

In an embodiment, the pair of frames (12) may be defined with a plurality of slots for accommodating the plurality of first ribs (13a) and the plurality of second ribs (13b). The top end (12x) of the pair of frames (12) may be machined with slots such that the depth of the slots is equivalent to the thickness of the plurality of first ribs (13a). The slots defined along the top end (12x) of the pair of frames (12) are configured such that the plurality of first ribs (13a) lie in flush with the top end (12x) of the pair of frames (12) and the plurality of first ribs (13a) lie in direct thermal contact with the enclosure (18) accommodated on the pair of frames (12). Further, the bottom end (12y) of the pair of frames (12) may be machined with slots such that the depth of the slots is equivalent to the thickness of the plurality of second ribs (13b). The slots defined along the bottom end (12y) of the pair of frames (12) are configured such that the plurality of second ribs (13b) lie in flush with the bottom end (12y) of the pair of frames (12) and the plurality of second ribs (13b) are in direct thermal contact with the enclosure (18) accommodated on the pair of frames (12). Consequently, the plurality first ribs (13a) and the plurality of second ribs (13b) conduct heat from the exhaust flowing through the exhaust tube (2) directly onto the enclosures (18) of the exhaust tube (2). Therefore, the heat conduction to the first conduction side (1a) in contact with the exhaust tube (2) is drastically improved and the overall operational efficiency of the system (100) is also improved.

In an embodiment, the least one enclosure (18) housed on the pair of frames (12) to form the exhaust tube (2) may be a sheet of material with predefined thickness, flatness, and surface roughness. The sheet material of the pre-defined dimensions may be used based on the required size of the exhaust tube (2) and other required parameters. The at least one enclosure (18) may be connected to the pair of frames (12) by any known means including but not limited to welding, brazing, preferably by means of bolts and nuts.

In an embodiment, the first ribs (13a) and the second ribs (13b) act as support structures for the at least one enclosure (18). The first ribs (13a) and the second ribs (13b) are spaced apart at a pre-determined distance such that the structural integrity of the at least one enclosure (18) is improved. Since, the exhaust tube (2) is subjected to high temperatures and high stresses during the flow of exhaust gases, the pair of frames (12a and 12b) including the at least one enclosure (18) tends to expand and contract at high rates. The first ribs (13a) and the second ribs (13b) may be configured such that the at least one enclosure (18) is firmly supported and the overall flatness of the at least one enclosure (18) is maintained throughout the length of the exhaust tube (2). Thus, the first ribs (13a) and the second ribs (13b) ensure that the overall flatness of the at least one enclosure (18) remains the same with minimal variations as the at least one enclosure is subjected to expansion and contraction during the flow of exhaust gases. Since, the overall flatness of the at least one enclosure remains the same due to the first ribs (13a) and the second ribs (13b), the contact between the first conduction side (1a) and the exhaust tube (2) is also retained throughout. The pair of frames (12a and 12b) of the exhaust tube (2) also include a plurality of extensions (21) which enable the stacking of the exhaust tube (2) in the system (100). The first ribs (13a) and the second ribs (13b) may be configured such that thickness and width gradually increases from the exhaust inlet (2a) to the exhaust outlet (2b). As seen from Fig. 8, the first ribs (13a) and the second ribs (13b) that are positioned proximal to the exhaust inlet (2a) may be of low thickness without a plurality of projections (13x). The thickness and the width of these projections (13x) may gradually increase on the first ribs (13a) and the second ribs (13b) that are positioned away from the exhaust inlet (2a). These projections (13x) may gradually increase in thickness on the plurality of ribs (13) extending from the exhaust inlet (2a) to the exhaust outlet (2b). Further, the thickness and the width of the first ribs (13a) and the second ribs (13b) may also gradually increase from the exhaust inlet (2a) to the exhaust outlet (2b). This configuration of the first ribs (13a) and the second ribs (13b) ensures a uniform distribution of heat throughout the exhaust tube (2). The exhaust gases when introduced into the exhaust tube (2) often tends to flow directly towards the exhaust outlet (2b) at high rate of flow. The high temperature exhaust gases often heat up the regions proximal to the exhaust inlet (2a) whereas, the heat transfer to the mid-region and the region proximal to the exhaust outlet (2b) is often insufficient. The temperature of the exhaust gases drops drastically after heating up the regions proximal to the exhaust inlet (2a). Consequently, only the regions proximal to the exhaust inlet (2a) is heated by the exhaust gases whereas the mid regions and the regions proximal to the exhaust outlet (2b) remains at a lower temperature compared to the other regions of the exhaust tube (2). The projections (13x) configured to the plurality of ribs (13a and 13b) proximal to the exhaust outlet (2b) resist the flow of exhaust gas and create turbulence to the flow of exhaust gases. Consequently, the exhaust gases tend to remain in the mid-regions and the region proximal to the exhaust outlet (2b) for a longer duration of time. Thus, the mid-regions and the region proximal to the exhaust outlet (2b) are also heated uniformly. With reference to Fig. 9a to Fig. 9g, the plurality of ribs (13) with projections are illustrated. The plurality of ribs (13) in the Fig. 9a to Fig. 9c are arranged or positioned proximal to the exhaust inlet (2a) of the exhaust tube (2). The plurality of ribs (13) in the Fig. 9d to Fig. 9g are arranged or positioned along the mid regions and the region proximal to the exhaust outlet (2b) of the exhaust tube (2) respectively. The dimensions of the plurality of ribs (13) increases gradually form the exhaust inlet (2a) and the projections (13x) may be introduced closer to the regions that lies proximal to the exhaust outlet (2b). The thickness of the projections (13x) on the plurality of ribs (13) may also increase gradually increase towards the exhaust outlet (2b). As, the dimensions of the projections (13x) increases and as the thickness of the plurality of ribs (13) increases from the exhaust inlet (2a), the resistance/turbulence offered by the plurality of ribs (13) to the flow of exhaust gases also increases. Consequently, the exhaust gases remain in the mid-region and the region proximal to the exhaust outlet (2b) for a longer duration of time when compared to the region proximal to the exhaust inlet (2a). The exhaust gases are thus retained in the mid-region and the region proximal to the exhaust outlet (2b) for a longer duration. Thus, the above-mentioned configuration of the plurality of ribs (13) ensures the uniform heating of the exhaust tube (2) as seen from Fig. 10.

With reference to the Fig. 9, the first ribs (13a) and the second ribs (13b) may be configured with the plurality of projections (13x) such that a corresponding slot (13y) is defined between each of the plurality of projections (13x). Further, the plurality of projections (13x) on the first ribs (13a) and the second ribs (13b) are configured such that, in an assembled condition, the projections (13x) on the first ribs (13a) lie in between the projections (13x) of the second ribs (1b) or along the slot (13y) of the second ribs (1b). In an embodiment, the plurality of projections (13x) on the first ribs (13a) and the second ribs (13b) may be configured such that, the projections (13x) on the second ribs (13b) lie in between the projections (13x) of the first ribs (1a) or along the slot (13y) of the first ribs (13a). Consequently, excessive the turbulence created by the first ribs (13a) and the second ribs (13b) against the flow of exhaust gases.

Fig. 11 illustrates an exploded perspective view of a stack of the exhaust tubes (2), the thermoelectric generators (1), and the coolant circuits (3). Fig. 12 illustrates an assembled perspective view of the stack of the exhaust tubes (2), the thermoelectric generators (1), and the coolant circuits (3). The thermoelectric generator (1) is sandwiched between the coolant circuit (3) and the exhaust tube (2). The first conduction side (1a) of the thermoelectric generator (1) is thermally connected to the exhaust tube (2) whereas, the second conduction side (1b) of the thermoelectric generator (1) is thermally connected to the coolant circuit (3). The first conduction side (1a) of the thermoelectric generator (1) may be thermally connected to the exhaust tube (2) with an intermediate thermal glue and a thermal interface. Similarly, the second conduction side (1b) of the thermoelectric generator (1) may also be thermally connected to the coolant circuit (3) with an intermediate thermal glue and the thermal interface. Further, another thermoelectric generator (1) may be housed on the other side of the exhaust tube (2). The first conduction side (1a) of the thermoelectric generator (1) may be housed on the other side of the exhaust tube (2) and the second conduction side (1b) of the thermoelectric generator (1) is thermally connected to another coolant circuit (3). Multiple coolant circuits (3) and exhaust tubes (2) may be stacked alternatively with thermoelectric generators (1) being positioned between each of the exhaust tube (2) and the coolant circuit (3). Each of the multiple thermoelectric generators (1) are configured such that the first conduction side (1a) is housed on the exhaust tube (2) whereas, the second conduction side (1b) is housed on the coolant circuit (3). The extensions (21) configured on the pair of frames (12) of the exhaust tube (2) and on the coolant circuit may accommodate a support structure (23). The support structures (23) may extend throughout the height of the stacked system (100). Further, the support structures (23) may be interconnected by a connecting plate (22) and the multiple fasteners (14). Thus, the stack of the exhaust tubes (2), the thermoelectric generators (1), and the coolant circuits (3) may be connected. The support structures (23) may be defined with multiple threads throughout. Initially, a fastener (14) may be inserted into each of the support structures (23) and the coolant circuit (3) may subsequently be inserted into the support structures (23) through the plurality of extensions (21) on the coolant circuit (3). Further, the second conduction side (1b) of the thermoelectric generators (1) may be positioned on the coolant circuit (3) and another set of fasteners (14) may be inserted over the support structure (23). The exhaust tube (2) may now be inserted though the support structure (23) by means of the extensions (21) defined on the exhaust tube (2) and the exhaust tube (2) may be inserted over the thermoelectric generators (1). Further, another set of fasteners (14) may be inserted through each of the support structures (23). Another layer of thermoelectric generators (1) may be positioned on the exhaust tube (2) such that the first conduction side (1a) of the thermoelectric generators (1) abuts the exhaust tube (2). Further, another coolant circuit (3) may be inserted followed by another layer of fasteners (14). In the above-mentioned manner each combination of the thermoelectric generator (1) and the coolant circuit (3) or each combination of the thermoelectric generator (1), the exhaust tube (2) and the coolant tube (3) may be secured together by fasteners (14) on the support structures (23). Thus, the fasteners (14) may be used to apply individual clamping force onto each of the combination of the thermoelectric generator (1), the exhaust tube (2) and the coolant tube (3). Since, the clamping force is individually applied by the fasteners (14) to the thermoelectric generators (1), the coolant tubes (3) and the exhaust tubes (2), the bottom most coolant circuit (3) and the thermoelectric generators (1) are prevented from being clamped with excessive force. Thus, the coupling force on each stack of the thermoelectric generator (1), the exhaust tube (2) and the coolant tube (3) is independent from each other or decoupled from each other.

With reference to Fig. 2, the exhaust gases are initially circulated into the exhaust tubes (2) though the exhaust inlet distributor (4). The exhaust gases enter the exhaust tube (2) through the inlet slot (4a) of the exhaust inlet distributor (4) and the exhaust inlet (2a) of the exhaust tube (2). As the exhaust gases flow through the exhaust tube (2), the exhaust tube (2) is heated. Since, the exhaust tube (2) is thermally connected to the first conduction side (1a) of the thermoelectric generator (1), the first conduction side (1a) is heated to high temperatures. As mentioned above, the configuration of the first ribs (13a) and the second ribs (13b) ensure the uniform heating of the exhaust tube (2) and the first conduction side (1a) of the thermoelectric generator (1). Further, coolant is simultaneously circulated thorough the coolant circuit (3) as the exhaust gases are circulated through the exhaust tube (2). The coolant is circulated through the inlet coolant tube (6) and the flexible connectors (8) to the coolant inlet (3a). The coolant enters the coolant circuit (3) through the coolant inlet (3a). The coolant further flows through the first coolant tube (10) and the second coolant tube (11) of the coolant circuit (3). The heat sink (9) further cools or reduces the temperature of the coolant flowing through the first coolant tube (10) and the second coolant tube (11). As the coolant flows through the coolant circuit (3), the second conduction side (1b) of thermoelectric generator (1) which is thermally connected to the coolant circuit (3) is cooled. This temperature gradient or the temperature difference between the first conduction side (1a) and the second conduction side (1b) of the thermoelectric generator (1), causes the thermoelectric generator (1) to generate electricity. This electricity may be harnessed and may be used to power the various appliances within the vehicle, or the generated electricity may be used for recharging the battery within the vehicle.

In an embodiment, the connection from output terminals of each of the thermoelectric generator (1) may be changed from series to parallel and vice versa for harnessing the power output from the thermoelectric generators (1) in the most efficient manner. A control unit may increase or decrease the series or parallel connection between the thermoelectric generators (1) based on various operational parameters for harnessing the maximum output from the thermoelectric generators (1). The varying or changing of the outlet connections of the thermoelectric generators (1) between series or parallel and vice-versa may be facilitated by any known means including but not limited to transistors. The operation of the transistors may be controlled by the control unit. Further, the temperature interface or the difference in temperature between the first conduction side (1a) and the second conduction side (1b) is different for different thermoelectric generators (1). When the temperature interface is different for different thermoelectric generators (1), the power output from the thermoelectric generators (1) also varies. For instance, when any two thermoelectric generators (1) having similar temperature interface are connected together in the parallel connection, the combined output from the two thermoelectric generators (1) is improved with minimal losses. However, if these two thermoelectric generators (1) having similar temperature interface are connected together in the series connection, the combined output from the two thermoelectric generators (1) is reduced. There are also scenarios where, connecting the thermoelectric generators (1) in series when there exists significant difference in temperature interface of the thermoelectric generators (1) will result in an output with minimal losses. Therefore, the control unit may monitor various parameters including the temperature interface of the thermoelectric generators (1) and may subsequently, pair the suitable thermoelectric generators (1) in the series or parallel connection to generate maximum or optimized output. In an embodiment, the control unit may monitor the temperature interface of each and every thermoelectric generator (1) for determining the output from each and every thermoelectric generator (1). In another embodiment, the control unit may only monitor the temperature of one of the thermoelectric generators (1) in each row or on each surface of the exhaust tube (2) and the coolant tube (3). The control unit may determine the overall temperature of the complete row of thermoelectric generators (1) based on the determined temperature interface of one of the thermoelectric generators (1) in each row. In another embodiment, the control unit may be configured to connect particular thermoelectric generators (1) in series connection or parallel connection based on results from a simulation. During a simulation, the temperature interface of each of the thermoelectric generators (1) is already estimated and the power output of each of the thermoelectric generators (1) is also estimated. Based on these estimated results, the control unit may couple the required thermoelectric generators (1) in series or parallel connection for obtaining an optimal output. In another embodiment, at least one of the temperatures of the exhaust gases at the exhaust inlet (2a) and the exhaust outlet (2b) of the exhaust tube (2) maybe monitored. Further, the temperatures of the coolant flowing through at least one of the coolant inlet (3a) and the coolant outlet (3b) of the coolant circuit (3) may also be monitored. The monitored temperatures may be used to simulate the optimal conditions for series and parallel connections of the thermoelectric generators (1). The data or the results from the simulation may be subsequently used to couple the required thermoelectric generators (1) in series or parallel connection for obtaining the optimal output.
In an embodiment, the flow of the exhaust gases in the exhaust tube (2) and the flow of the coolant in the coolant circuit (3) may be along the same direction or in a direction opposite to each other i.e., the flow of the exhaust gases in the exhaust tube (2) and the flow of the coolant in the coolant circuit (3) may be in parallel or counter flow arrangement.

Fig. 13 illustrates an embodiment of the exhaust heat thermoelectric generator system (100) with an auxiliary heat exchanger (15). In this embodiment, the above-described system (100) is configured with an additional heat exchanger (15). The inlet coolant tube (6) is connected to an inlet of the auxiliary heat exchanger (15) and an outlet of the auxiliary heat exchanger (15) is connected to the outlet coolant tube (7). The coolant from the coolant circuit (3) is circulated though the auxiliary heat exchanger (15). The auxiliary heat exchanger (15) reduces the temperature of the coolant to a greater extent and thereby, the cooling of the second conduction side (1b) of the thermoelectric generator (1) in contact with the coolant circuit (3) is also enhanced. In an embodiment, the height difference between the system (100) and the auxiliary heat exchanger (15) is configured such that the coolant flow between the coolant circuit (3) and the auxiliary heat exchanger (15) occurs through siphon circulation. Thus, the flow of coolant between the coolant circuit (3) and the auxiliary heat exchanger (15) may be enabled without an external pump.

In an embodiment, the system (100) may be configured such that the heat sink (9) in the coolant circuit (3) lies parallel and proximal to the radiator grill of the vehicle for guiding the incoming air directly onto the heat sink (9). In another embodiment, the auxiliary heat exchanger (15) may also be positioned to lie parallel and proximal to the radiator grill of the vehicle.

In an embodiment, the system (100) may be integrated along a tailpipe region of the exhaust pipe in the vehicle. The exhaust gases may thus directly enter the exhaust tube (2) of the system (100). In an embodiment, the system (100) may be configured before or after an exhaust muffler. The positioning of the system (100) in the vehicle must not be considered as a limitation as the system may be placed anywhere in the vehicle and the exhaust gases may be re-directed to the system (100).

In an embodiment, the malleable/flexible nature of the flexible connectors (8) ensures that the connection between the coolant circuit (3), the inlet coolant tube (6) and the outlet coolant tube (7) remain intact irrespective of the road conditions that the vehicle traverses over. For instance, as the vehicle traverses over bumps, potholes or other un-even surfaces, the flexible connectors (8) absorb the impact of the un-even surfaces. Unlike conventional connectors that may be rigid leading to failure upon minor impacts, the flexible connectors (8) deform and return to their original shapes as the vehicle traverses over un-even surfaces and thereby prevent the premature failure of the system (100).

In an embodiment, the malleable/flexible nature of the flexible connectors (8) between the coolant circuit (3), the inlet coolant tube (6) and the outlet coolant tube (7) compensate for manufacturing tolerances which may add up due to stacking of multiple coolant circuits (3). For instance, when multiple coolant circuits (3) are stacked one upon the other, the connectors may not always facilitate an accurate link if the connectors are rigid due to slight variations in the manufacturing tolerances. Accordingly, flexible connectors (8) deform and adapt to the variations or changes in the manufacturing tolerances.

In an embodiment, the control unit actuates the bypass valve (16a) based on the signals from the temperature sensor [Not shown] and when the detected signals exceed the pre-determined threshold limit. In an embodiment, the duct (16) and the bypass valve (16a) enable the direct flow of the exhaust gases from the exhaust inlet distributor (4) to exhaust outlet distributor (5) and prevent the thermoelectric generators from being damaged by exposure to very high temperatures of the exhaust gases.

In an embodiment, the coolant circuit (3) including the heat sink (9) that is sandwiched between the first coolant tube (10) and the second coolant tube (11) contributes towards the further reduction of temperature of the coolant. Consequently, the second conduction side (1b) of thermoelectric generator (1) is cooled to a greater extent and the operational efficiency of the system (100) is improved.

In an embodiment, the exhaust tube (2) is assembled with fasteners (14 and 14a) without any hot working process such as welding or brazing. Consequently, the operational life of the exhaust tube (2) is drastically improved as there are no weld joints or any other joining processes enabled by the hot working process which may lead to the pre-mature failure of the exhaust tube (2).

In an embodiment, the first ribs (13a) and the second ribs (13b) act as support structures for the at least one enclosure (18). The first ribs (13a) and the second ribs (13b) are spaced apart at a pre-determined distance such that the structural integrity of the at least one enclosure (18) is improved. The first ribs (13a) and the second ribs (13b) may be configured such that the at least one enclosure (18) is firmly supported and the overall flatness of the at least one enclosure (18) is maintained throughout the length of the exhaust tube (2). Consequently, the contact between the first conduction side (1a) and the exhaust tube (2) is also retained throughout. Therefore, the first conduction side (1a) is subjected to uniform heating and the overall operational efficiency of the system (100) is vastly improved.

In an embodiment, the thickness, and the width of the first ribs (13a) and the second ribs (13b) may also gradually increase from the exhaust inlet (2a) to the exhaust outlet (2b). This configuration of the first ribs (13a) and the second ribs (13b) ensures a uniform distribution of heat throughout the exhaust tube (2).

In an embodiment, the above-described system (100) consumes lesser space compared to conventional Rankine cycle systems and may easily be accommodated in the vehicle. In an embodiment, the above-described system (100) may be retro-fitted onto existing vehicles with minimal changes to the exhaust flow system.

In an embodiment, the above-mentioned system (100) must not be limited to use in the vehicle with exhaust heat gases. The system (100) may be used anywhere that facilitates or provides an heat source for heating the first conduction side (1a) and a cooling source for cooling the second conduction side (1b) of the thermoelectric generator (1). The above-mentioned system (100) may be used alongside diesel generators, ocean thermal energy conversion systems etc.

Equivalents

With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.

It will be understood by those within the art that, in general, terms used herein, are generally intended as "open" terms (e.g., the term "including" should be interpreted as "including but not limited to," the term "having" should be interpreted as "having at least," the term "includes" should be interpreted as "includes but is not limited to," etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding the description may contain usage of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an" (e.g., "a" and/or "an" should typically be interpreted to mean "at least one" or "one or more"); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of "two recitations," without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to "at least one of A, B, and C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, and C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to "at least one of A, B, or C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, or C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase "A or B" will be understood to include the possibilities of "A" or "B" or "A and B."

While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated in the description.

Referral Numerals:

Referral numerals Description
1 Thermoelectric generator
1a First conduction side
1b Second conduction side
2 Exhaust pipe
2a Exhaust inlet
2b Exhaust outlet
3 Coolant circuit
3a Coolant inlet
3b Coolant outlet
4 Exhaust inlet distributor
4a Exhaust inlet slot
5 Exhaust outlet distributor
5a Exhaust outlet slot
6 Inlet coolant tube
7 Outlet coolant tube
8 Flexible connectors
9 Heat sink
10 First coolant tube
11 Second coolant tube
12, 12a, 12b Frame
13 Ribs
13a First ribs
13b Second ribs
14, 14a Fasteners
15 Auxiliary heat exchanger
16 Duct
16a Bypass valve
18 Enclosure
21 Extension
22 Connecting plate
23 Support structure
100 System