Design and development of a high power density portable thermoelectric generator

In this paper, the basic design problems encountered in the development of a forced convection cooled light-weight portable thermoelectric generator are discussed and analyzed. These problems are fundamentally a question of the proper integration and optimization of the propane heat source and forced convection cooling system within the engineering restrictions imposed by the mechanical and thermoelectric properties of present day thermoelements. These restrictions involve the effect of contact resistance, figure of merit, life, and allowable stresses in the thermoelements and place limitations on the hot side temperature, physical constraint of the thermoelements, and allowable heat flux density. These parameters then directly effect the weight, power density, and efficiency of the final unit. This paper emphasizes the importance of the engineering relations between these parameters and describes in detail a specific design solution to the problems involved giving performance for the fabricated unit.