Achieving 12.7% energy conversion efficiency in segmented GeTe/BST-SKD thermoelectric modules via broad-temperature and structural optimizations
摘要
Solid-state thermoelectric (TE) power generation through the direct conversion of a temperature difference into electricity has received worldwide attention. In this work, a segmented GeTe/BST-SKD TE module is optimized and fabricated to achieve outstanding power density and energy conversion efficiency. To enable high module-level TE performance, p-type GeTe with a ZTmax of 2.47 is used, while p-type BST (Bi2−xSbxTe3, with high ZT in the low temperature range) and n-type SKD (skutterudite, Yb0.3Co4Sb12) are optimized to reach ZTmax values of 1.38 and 1.33, respectively. Furthermore, module structure optimization is conducted using multiphysics-field simulations for three shape factors, including the segmentation ratio, height-to-area ratio, and cross-sectional area ratio between p- and n-type legs. When the three factors are 0.35, 0.67 mm−1, and 1.85, respectively, both the maximum power density and energy conversion efficiency reach their optimal values. Finally, Ni foil is applied at the GeTe/BST interface to serve as both a metallization layer and a diffusion barrier, minimizing internal contact resistances and enhancing high-temperature stability. The maximum power density and energy conversion efficiency of the segmented module are increased by 35% and 21 %, respectively, compared with those of the unsegmented one. The segmented module achieves a substantial power output of ∼0.43 W at ΔT = 500 K, corresponding to a power density of 0.35 W/cm2 per module area and 143 W kg−1 per module weight, with an effective material-level power density of 1.51 W/cm2. The segmented module achieves an outstanding energy conversion efficiency of 12.7%, demonstrating the effectiveness of the optimized leg-segmentation strategy for highperformance solid-state energy harvesting.