Search

The rapid enhancement of the thermoelectric (TE) figure‐of‐merit (zT) in the past decade has opened opportunities for developing and transitioning solid state waste heat recovery systems. Here, a segmented TE device architecture is demonstrated in conjunction with heterogeneous material integration that results in high unicouple‐level conversion efficiency of 12% under a temperature difference of 584 K. This breakthrough is the result of success in fabricating bismuth telluride/half‐Heusler segmented TE unicouple modules using a "hot‐to‐cold" fabrication technique that provides significantly reduced electrical and thermal contact resistance. Extensive analytical and finite element modeling is conducted to provide an understanding of the nature of thermal transport and contributions arising from various thermal and physical parameters. Bismuth telluride/half‐Heusler based segmented thermoelectric generators (TEGs) can provide higher practical temperature difference with optimum average zT across the whole operating range. These results will have immediate impact on the design and development of TEGs and in the general design of devices based upon heterostructures that take advantage of gradients in the figure of merit. [ABSTRACT FROM AUTHOR]

Thermoelectric skutterudite materials have been widely investigated for their potential application in mid-temperature waste heat recovery that has not been efficiently utilized A large amount of research has focused on developing materials with a high thermoelectric figure of merit (zT). However, the translation of material properties to device performance has limited success. Here, we demonstrate single-filling n-type Yb0.25Fe0.25Co3.75Sb12 and multi-filling La0.7Ti0.1Ga0.1Fe2.7Co1.3Sb12 skutterudites with a maximum zT of ~1.3 at 740 K and ~0.97 at 760 K. The peak zT of skutterudites usually occurs above 800 K, but, as shown here, the shift in peak zT to lower temperatures is beneficial for enhancing conversion efficiency at a lower hot-side temperature. In this work, we have demonstrated that the Fe-substitution significantly reduces the thermal conductivity of n-type skutterudite, closer to p-type skutterudite thermal conductivity, resulting in a module that is more compatible to operate at elevated temperatures. A uni-couple skutterudite module was fabricated using a molybdenum electrode and Ga–Sn liquid metal as the thermal interface material. A conversion efficiency of 7.27% at a low temperature gradient of 366 K was achieved, which is among the highest efficiencies reported in the literature at this temperature gradient. These results highlight that peak zT shift and optimized module design can improve conversion efficiency of thermoelectric modules at a low temperature gradient. [ABSTRACT FROM AUTHOR]

Solid-state thermoelectric generators (TEGs) are promising solution for waste heat recovery. However, they typically suffer from lower conversion efficiency, lack of reliable high temperature device fabrication process and long-term stability. In order to realize high electrical conversion efficiency (ECE) in TEGs, it is critical that in conjunction with high TE materials figure of merit, zT, there is also a reliable TE module fabrication process. This study demonstrates the TEG fabrication process that results in reduced thermal and electrical contact resistances between metal electrodes and TE legs, even at high temperatures (>600 °C). The fabrication approach is demonstrated using p-type ZrCoSb-based and n-type ZrNiSn-based half-Heusler TE materials. High temperature brazing material is used as a filler that enables direct bonding of TE legs to the copper electrode without metallizing legs. This technique improves the TEG performance and stability at high temperatures by minimizing the contact resistance and diffusion at TE leg/electrode interface. The fabricated modules exhibit a high power density of ~11.5 Wcm−2 and an ECE of 9.5% at 670 °C temperature gradient. The module was exposed to longtime soaking at 550 °C in air and was found to exhibit negligible deterioration. These results are highly promising for advancing the TE modules in waste heat recovery applications. [Display omitted] • High-performance half-Heusler device is fabricated for waste heat recovery. • Demonstration of cost-effective and rapid half-Heusler device fabrication process. • Innovation in fabrication technique resulting in elimination of metallization step. • Contact resistance and diffusion at leg/electrode interface are minimized. • Module demonstrated high power density of ~11.5 Wcm−2 and efficiency of 9.5%. [ABSTRACT FROM AUTHOR]