Enhanced Performance of Monolithic Chalcogenide Thermoelectric Modules for Energy Harvesting via Co-optimization of Experiment and Simulation

With the development of application of wireless sensor nodes (WSNs), the need for energy harvesting is rapidly increasing. In this study, we designed and fabricated a robust monolithic thermoelectric generator (TEG) using a simple, low-energy, and low-cost device fabrication process. Our monolithic device consists of Ag2S0.2Se0.8 and Bi0.5Sb1.5Te3 as n-type and p-type legs, respectively, while the empty space between the legs was filled with highly dense, flexible, and thin Ag2S that serves as both an insulating spacer and a shock absorber, which potentially augments the robustness of preventing from damage from an external mechanical force. From the optimization of the device structure via finite element method (FEM) simulations, a three-pair device with dimensions of 12 mm × 10 mm × 10 mm was found to have a theoretical maximum power density of 8.2 mW cm–2 at a ΔT of 50 K. For considering this inevitable contact resistance, experimental measurement and FEM simulation were combined for quantifying the junction resistance; a power density of 2.1 mW cm–2 was established with the consideration of the contact resistance at the p–n junctions. Using these optimized structural parameters, a device was fabricated and was found to have a maximum power density of 2.02 mW cm–2 at a ΔT of 50 K, which is in good agreement with our simulations. The results from our monolithic TEG show that despite the simple, low-energy, and low-cost device fabrication process, the power generation is still comparable to other reported TEGs. It is worth mentioning that our design could be extended to other chalcogenide materials of appropriate temperature regions and/or better zT. Besides, the quantification of contact resistance also exhibited reference value for the enhancement of thermoelectric conversion application. These results provide a convenient, economic, and efficient strategy for waste energy harvesting close to room temperature, which can broaden the applications of waste heat harvesting.