Conformal High-Power-Density Half-Heusler Thermoelectric Modules: A Pathway toward Practical Power Generators

Area of Science:

• Materials Science
• Energy Conversion
• Solid State Physics

Background:

• Thermoelectric generators (TEGs) are crucial for waste heat recovery via the Seebeck effect.
• Half-Heusler (hH) alloys are promising for medium- to high-temperature thermoelectric power generation.
• Existing TEGs face challenges with material uniformity, low power output, and rigid form factors.

Purpose of the Study:

• To develop large-diameter wafers with uniform thermoelectric properties.
• To create high-power, conformal hH TE modules for high-temperature applications.
• To demonstrate direct integration of flexible TEGs on flue gas platforms.

Main Methods:

• Fabrication of large-diameter hH alloy wafers with uniform properties.
• Development of a conformal architecture for TE modules.
• Integration of modules onto cylindrical flue gas platforms.

Main Results:

• Demonstrated uniform TE properties on large wafers.
• Achieved high-power conformal hH TE modules with a power density of 3.13 W cm⁻².
• Modules generated 56.6 W at a temperature difference of 570 °C.

Conclusions:

• The conformal design offers a breakthrough for medium-/high-temperature TEGs, surpassing conventional designs.
• This flexible TEG architecture enhances device performance and flexibility.
• The technology paves the way for widespread waste heat recovery and practical thermal-to-electrical converters.