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Optimal leg ratio design for segmented thermoelectric generator via thermal conductivity matching

Author

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  • Liu, Quan
  • Zhou, Jiayu
  • Huang, Libing
  • Lin, Jianping

Abstract

Segmented thermoelectric generators (STEGs) can enhance the efficiency of wide-temperature-range TEGs by utilizing the characteristics of thermoelectric materials. However, the rational design of legs that balances cost, conversion efficiency, and stability remains challenging. In this study, a thermal conductivity matching strategy is proposed, which can rapidly optimize leg geometry and material selection for STEGs. Multi-physics field simulation studies were conducted on the Zn4Sb3/In4Se3-Bi2Te3 (Z/I-BSTEGs) and Skutterudites-Bi2Te3 (S-BSTEGs) systems. The optimal performance of Z/I-BSTEGs is achieved when θ (the length ratio of segmented legs) is close to 1/4 (θ = 1/4, output power = 4.31 W, η = 8.63 %, ΔT = 460 K)—the output power is 5.9 times that of ZnSb/InSe-based TEGs, and the conversion efficiency exceeds that of commercial BiTe modules by 32.7 %. The performance reaches a peak when the segmented interface temperature matches the optimal ZT of TE leg and the thermal conductivity ratio is directly correlated with the ideal leg length ratio (e.g., Khot,p/Kcold,p = 1/3.04, Khot,n/Kcold,n = 1/4.04 in Z/I-BSTEGs with θ ≈ 1/4). This conclusion is similarly validated in S-BSTEGs. Mechanistically, the peaks of stress and deformation increase with increasing θ, and the thermal conductivity matching strategy effectively reduces thermomechanical stress. The optimized configuration of Z/I-BSTEGs achieves collaborative optimization of high efficiency and low stress-deformation (1464.40 MPa and 21.45 μm) with a shorter combination of segmented legs. Based on a leg combination design guided by thermal conductivity (κ), this study provides a universal route for the development of compact, low-cost STEGs with both high efficiency and stability.

Suggested Citation

  • Liu, Quan & Zhou, Jiayu & Huang, Libing & Lin, Jianping, 2025. "Optimal leg ratio design for segmented thermoelectric generator via thermal conductivity matching," Energy, Elsevier, vol. 339(C).
    • Handle: RePEc:eee:energy:v:339:y:2025:i:c:s0360544225047152
    DOI: 10.1016/j.energy.2025.139073
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