Abstract
Finite-element simulation of a thermoelectric (TE) module was conducted to optimize its geometrical dimensions in terms of mechanical reliability and performance. The TE module consisted of bismuth telluride n- and p-type legs. The geometrical dimensions of the module, i.e., leg length and leg cross-sectional area, were varied, and the corresponding maximum thermal stress, output power, and efficiency of the module obtained. An optimal design for the module was then suggested based on minimizing the thermal stresses and maximizing the performance, i.e., power and efficiency. The optimal dimensions at maximum von Mises stress of 75 MPa were leg length of 2 mm to 2.5 mm and leg width of 1.5 mm to 2 mm, resulting in efficiency of 7.2%. Finally, the influence of solders, i.e., solder material between the leg, the interconnector, and the top ceramic layer, on the induced thermal stresses and module performance was investigated. The results revealed that the transition from elastic to plastic deformation in the solder decreased the induced thermal stresses significantly. Moreover, beyond the elastic limit, the stress magnitude was highly dependent on the magnitude and mechanism of plastic deformation in the module. The present study provides a basis for a unique and new optimization scheme for TE modules in terms of endurance and performance.
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Acknowledgements
The authors would like to thank the Programme Commission for Energy and Environment (EnMi), The Danish Research and Innovations (Project No. 10-093971) for sponsoring the OTE-POWER research work as well as supporting the CTEC project.
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Sarhadi, A., Bjørk, R. & Pryds, N. Optimization of the Mechanical and Electrical Performance of a Thermoelectric Module. J. Electron. Mater. 44, 4465–4472 (2015). https://doi.org/10.1007/s11664-015-3977-0
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DOI: https://doi.org/10.1007/s11664-015-3977-0