A Comprehensive Study on X-Type Thermoelectric Generator Modules

This paper focuses on studying the feasibility of an X-type thermoelectric module with different draft angles. A three-dimensional finite element model is established to analyze the thermoelectric and mechanical performance under steady-state conditions. Temperature, output power, conversion efficiency, and thermal stress are evaluated under four draft angles of 10°, 20°, 30°, and 40°. The numerical results indicate that the maximum output power of the X-type thermoelectric module is reached when θ = 10°, and it is about 4.57% higher than that of the traditional structure. The maximum von Mises stress occurs on four corners of the hot-side surfaces of the thermoelectric legs, and it decreases with an increase in the draft angle, while at the same time the von Mises stress on the middle surface is continuously increased. Additionally, shorter legs not only improve the output power, but can also enhance the mechanical performance. It can be concluded, therefore, that the design of the X-type structure with a certain draft angle can enhance the performance of the thermoelectric module with regard to both electrical power and mechanical reliability. The findings of this work may provide a basis for optimization of thermoelectric modules.