Modeling study on the geometric optimization of thermoelectric modules

Abstract The performance of thermoelectric power generators (TEG) primarily depends on the properties of the thermoelectric materials employed. For conventional thermoelectric modules (TEM) utilizing the same material, the geometric parameters also play a significant role in determining TEM performance. As such, optimizing the geometry of TEM can lead to improved performance. In this study, TEM were modeled, designed, fabricated, and tested to investigate the effects of different geometric parameters on their performance. Numerical simulations were conducted under both constant temperature and constant flow boundary conditions, and the results were validated through experimental testing. The simulation results under constant flow boundary conditions exhibited good agreement with the experimental results. The effects of thickness, cross-sectional area, and filling ratio of thermoelectric legs on TEM performance were investigated through numerical simulations and compared with findings from previous studies. It was observed that increasing the cross-sectional area of the thermoelectric legs led to a decrease in the power output of TEM. Conversely, increasing the filling ratio effectively enhanced the TEM's performance. Furthermore, an optimal thermoelectric leg thickness was identified through the numerical simulations that could yield the maximum power output of TEM. The underlying mechanism behind this observation was explained, shedding light on why different reports have identified different optimal thicknesses. Optimizing the thermoelectric leg thickness can help maintain a high effective temperature difference and low internal resistance, which can vary based on the specific type of TEM and the thickness and thermal conductivity of the insulating substrates and copper sheets.