Improving Thermal Shields to Protect Thermoelectric Generators (TEGS) in Automotive Energy Recovery Systems

The increasing need for sustainable mobility and enhanced energy efficiency in internal combustion engine (ICE) vehicles has intensified interest in waste heat recovery technologies, particularly thermoelectric generators (TEGs). However, low conversion efficiency and sensitivity to high exhaust gas temperatures from internal combustion engines still limit their practical application.

This study investigates the thermal and electrical behavior of a commercial TEC1-12706 SR module subjected to controlled temperature conditions that simulate exhaust system environments. Using copper and aluminum protective plates to manage heat distribution, experiments were conducted at input temperatures of 250°C and 350°C to assess temperature evolution, thermal gradients, voltage, current, and output power. Copper’s high thermal conductivity facilitated efficient heat transfer on the hot side, while aluminum increased distribution of thermal dissipation on the cold side, though progressive heating reduced ΔT over time. The findings underline the critical role of thermal shielding and cooling strategies in preserving module integrity and maximizing conversion efficiency. This research provides experimental insights and design considerations for integrating TEGs into automotive waste heat recovery systems.