Fraunhofer Institute for Physical Measurement Techniques IPM
Fraunhofer Institute for Physical Measurement Techniques IPM

Customized thermoelectric modules and systems

Fraunhofer IPM develops and manufactures thermoelectric modules for the specific requirements of customers in the space industry. We specialize in the production of thermoelectric legs in custom-tailored geometries in a variety of aspect ratios and edge lengths. For our customers in the aerospace sector, we design individual solutions that ensure optimal performance. Full thermoelectric simulations are used to adapt the modules to each specific application.

In a number of different research projects, we have engineered reliable thermoelectric modules and systems to withstand the extreme conditions of outer space. We collaborate closely with customers and research partners to ensure that our thermoelectric modules comply with ECSS standards. 

 

An exemplary selection of past publicly funded projects related to thermoelectric modules is shown below. In recent years, the focus of activities at Fraunhofer IPM has shifted from thermoelectric energy harvesting to Peltier cooling.

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Thermoelectric Converter System for Small-Scale RTGs 

Fraunhofer IPM was involved in project “ssRTG - Thermoelectric Converter System for Small-Scale RTGs”,  funded by the European Space Agency (ESA). The scientists at Fraunhofer IPM were responsible for developing a high-power thermoelectric generator (TEG) module, including the necessary thermoelectric material and joining technology, for a radioisotope thermoelectric generator (RTG) system. The project resulted in the successful development and testing of a 5-watt breadboard RTG. This was the first time a prototype RTG system had been developed and tested outside of the US and Russia. The project advanced the technology readiness level of the European RTG program from TRL 0 to TRL 3/4.

Accelerated Metallurgy – the accelerated discovery of alloy formulations using combinatorial principles

With its expertise in thermoelectric materials, Fraunhofer IPM participated in the ACCMET project, which was funded by the European FP7-NMP program and coordinated by the European Space Agency (ESA). The core concept of the Accelerated Metallurgy project was to combine additive manufacturing and high-throughput technology to accelerate the workflow for developing and optimizing new alloy formulations. 
The most promising alloy formulations were scaled up and tested further for exploitation by the 20 end users within Accelerated Metallurgy. The project addressed industrial interests for aerospace applications, such as rockets, gas turbines, and jet engines. Major aerospace stakeholders (Airbus, Norsk Titanium, AVIO, and Rolls-Royce) were closely involved in the research and evaluation of results. The culmination of ACCMET project activities was a full demonstration in the form of an integrated pilot facility. 

Nanostructured energy-harvesting thermoelectrics based on Mg2Si

Fraunhofer IPM made a significant contribution to the project "THERMOMAG - Nanostructured energy-harvesting thermoelectrics based on Mg2Si."  The project explored low-cost, lightweight thermoelectric materials and demonstrator modules for harvesting waste heat. The project yielded promising n-type and p-type silicide-based materials, as well as prototype modules that were assembled to evaluate real-world performance and durability. These materials are promising for space applications due to their light weight and composition of abundant, non-toxic elements. In conclusion, the project yielded viable, low-mass thermoelectric materials and operational prototypes with clear relevance to space applications. 

Self-sufficient, flexible monitoring devices for controlling technical systems

As part of the project, a thermoelectrically powered sensor node was developed for monitoring the outer skin of an aircraft. The thermal coupling of the thermoelectric generators to the aircraft skin had to be robust enough to withstand the temperature fluctuations and vibrations typical in aircraft. At the same time, the TE generators had to provide sufficient power to operate low-power radio electronics.
Through optimal integration, the electrical power yield of the thermoelectric generators was increased by a factor of ten. The design of the thermal coupling was supported by climate chamber, temperature shock, and vibration tests. The final version of the thermoelectric generator developed proved to be robust against both the temperature shock and vibration profiles required in the aircraft.

Funding: Federal Ministry of Research, Technology and Space (formerly; Federal Ministry of Education and Research) 

Project term: 2008/11–2012/04