Additive fabrication and experimental validation of a lightweight thermoelectric generator

We develop a thermoelectric generator based on catalytic combustion and operating in the low power range (up to 10 W). Considering the target of small-scale thermoelectric generators, the additive technique was chosen as an enabling technology to customize the different parts of the presented device. The generator consists of a hexagonal shaped combustion chamber coupled to commercial thermoelectric modules, water-cooled at the cold side. Thanks to the components design, heat transfer across each part of the system is properly driven enhancing the thermal management of the system. Moreover, in order to improve the overall efficiency, exhausts outlet is designed to promote heat recovery. The generator is characterized achieving an electrical power output close to 9 W in continuous regime, with an overall efficiency of 3.55%. The compact size, the light weight, the simple design and the reliability in continuous operating conditions are all promising features of the device described. Furthermore, the materials chosen for the device can suggest a way to fabricate cheaper heat exchangers, actually one of the main costs of the device development.