Module geometry and contact resistance of thermoelectric generators analyzed by multiphysics simulation

Thermoelectric device performance is determined by not only the properties of the thermoelectric material but also the geometrical design and thermal matching of the materials. Leg length and contact quality strongly influence thermoelectric generator efficiency. Experimental results for contact properties are compared with the latest performance measurements on modules manufactured from Bi2Te3 compounds. Module performance is related to the obtained contact resistance and thermoelectric material properties. The different influences are studied using thermoelectric multiphysics finite-element modeling of examples where, in addition to the thermoelectric field equations, further effects such as convection and radiation as well as the temperature dependency of the material properties are taken into account. Extensive thermoelectric device modeling is used to understand the experimental findings with respect to contact properties and geometry.