Development of An Underarmor 10 Kilowatt Thermoelectric Generator Waste Heat Recovery System for Military Vehicles

Hi-Z will complete the design of a 10 kilowatt waste heat recovery thermoelectric generator that can be used on the Army’s Stryker and other similar vehicles. One or more advanced quantum well thermoelectric modules with at least three times the efficiency of today’s Bi2Te3 thermoelectrics will be fabricated and tested in the generator. DOD, DOE and NASA presently fund quantum well film development at Hi-Z and this support allows the module fabrication development to proceed at an accelerated pace. Hi-Z's Phase I results on a preliminary design of a quantum well thermoelectric generator, quantum well materials tests, as well as 500,000 miles on a conventional Hi-Z thermoelectric generator on a diesel truck exhaust in a companion program, highlight the viability of this high efficiency quantum well generator approach. The quantum well module development includes a high heat flux eggcrate, quantum well film production, element contact resistance reduction, bonding development, film assembly in eggcrate, and compression design with testing and fabrication qualification of numerous 2-Watt mini-modules which are the basic building blocks for 50 Watt modules. The generator will also be configured and fabricated to operate as a separate APU with the addition of a diesel fuel burner, blower and control system. Proof of generator design will be confirmed with both a mock-up and with advanced quantum well modules.