Design of a High-Performance Thermoelectric Generator with Exhaust Gas-Induced Airflow Cooling

The efficiency of the commercial thermoelectric generators (TEGs) is strongly constrained by the limited temperature gradient that can be maintained across the thermoelectric modules, which in turn is governed by the performance and energy demand of the cooling system. Conventional active cooling solutions improve heat dissipation but reduce net power output due to parasitic energy consumption, while passive air cooling typically provides insufficient heat transfer. In this work, a thermoelectric generator incorporating an exhaust gas-induced airflow cooling system is proposed as an energy-autonomous alternative that enhances heat rejection without external power input. The proposed cooling concept utilizes the natural draft created by hot exhaust gases to generate forced laminar airflow through compact air radiators, enabling effective stabilization of the cold-side temperature. In parallel, a new thermoelectric unicouple design based on Bi 2 Te 3 -derived materials is developed, featuring a segmented p -type leg and an optimized n -type leg. The geometry of the unicouple and the segment dimensions were optimized by accounting for temperature-dependent material properties, contact resistances, and heat losses. An analytical model combining thermal and hydraulic analyses was formulated and validated using finite-element simulations. The combined optimization of the cooling system and thermoelectric module leads to a 1.5–2.5-fold increase in energy conversion efficiency compared with commercial gas-fueled TEGs, demonstrating a practical route toward efficient and reliable energy conversion.