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Thermoelectric generator is a device taking advantage of the temperature difference in thermoelectric material to generate electric power, where the higher the temperature difference of the hot-cold ends, the higher the efficiency will be. However, higher temperature or higher heat flux upon the hot end will cause strong thermal stress which will negatively influence the lifecycle of the thermoelectric module. This phenomenon is very common in industrial applications but seldom has research work been reported. In this paper, numerical analysis on the thermodynamics and thermal stress performance of the thermoelectric module has been performed, considering the variation on the thickness of materials; the influence of high heat flux on thermal efficiency, power output, and thermal stress has been examined. It is found that under high heat flux imposing upon the hot end, the thermal stress is so strong that it has a decisive effect on the life expectation of the device. To improve the module’s working condition, different geometrical configurations are tested and the optimum sizes are achieved. Besides, the side effects on the efficiency, power output, and open circuit voltage output of the thermoelectric module are taken into consideration. [ABSTRACT FROM AUTHOR]

In order to improve the performance and maximize the efficiency of energy conversion of thermoelectric generator (TEG), a mathematical model to predict the maximum energy conversion efficiency of TEG is developed. Then, a new compact thermoelectric generator (C-TEG) and a dimensional optimized TEG (DO-TEG) are proposed in this article. The compact thermoelectric generator is designed via logical intersection angle selection and layout, thus to improve the electric performance per unit volume. Finally, we compared the output electric performance of C-TEG and traditional thermoelectric generator (T-TEG) and that of DO-TEG under design and off-design conditions via numerical simulations. The results indicate that C-TEG has an excellent electric performance whose voltage, power, and efficiency decrease slightly whereas the output voltage, work, and efficiency compared with that of T-TEG have been significantly improved, with the amplitude increasing with the increase of resistant value of external loads. [ABSTRACT FROM AUTHOR]