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Processes
Volume 13
Issue 6
10.3390/pr13061931
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This is an early access version, the complete PDF, HTML, and XML versions will be available soon.
Review

Review of Automotive Thermoelectric Generator Structure Design and Optimization for Performance Enhancement

by
Yue Wang
1,2,
Ruochen Wang
1,*,
Ruiqian Chai
2,
Renkai Ding
3,
Qing Ye
3,
Zeyu Sun
4,
Xiangpeng Meng
3 and
Dong Sun
1
1
School of Automotive and Traffic Engineering, Jiangsu University, Zhenjiang 212013, China
2
School of Mechanical and Electrical Engineering, Chuzhou University, Chuzhou 239000, China
3
Automotive Engineering Research Institute, Jiangsu University, Zhenjiang 212013, China
4
School of Agricultural Engineering, Jiangsu University, Zhenjiang 212013, China
*
Author to whom correspondence should be addressed.
Processes 2025, 13(6), 1931; https://doi.org/10.3390/pr13061931
Submission received: 12 May 2025 / Revised: 5 June 2025 / Accepted: 16 June 2025 / Published: 18 June 2025
(This article belongs to the Section Energy Systems)
Versions Notes

Abstract

Thermoelectric generator (TEG) has emerged as a critical technology for automotive exhaust energy recovery, yet there is still a lack of reviews analyzing automotive TEG structure design and optimization methods simultaneously. Therefore, this review consolidates structure design and methods for improving thermoelectric conversion efficiency, focusing on three core components: thermoelectric module (TEM), heat exchanger (HEX), and heat sink (HSK). For TEM, research and development efforts have primarily centered on material innovation and structural optimization, with segmented, non-segmented, and multi-stage configurations emerging as the three primary structural types. HEX development spans external geometries, including plate, polygonal, and annular designs, and internal enhancements such as fin, heat pipe, metal foam, and baffle to augment heat transfer. HSK leverages active, passive, or hybrid cooling systems, with water-cooling designs prevalent in automotive TEG for cold-side thermal management. Optimization methods encompass theoretical analysis, numerical simulation, experimental testing, and hybrid methods, with strategies devised to balance computational efficiency and accuracy based on system complexity and resource availability. This review provides a systematic framework to guide the design and optimization of automotive TEG.
Keywords: thermoelectric generator; thermoelectric module; heat exchanger; heat sink; optimization method thermoelectric generator; thermoelectric module; heat exchanger; heat sink; optimization method

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MDPI and ACS Style

Wang, Y.; Wang, R.; Chai, R.; Ding, R.; Ye, Q.; Sun, Z.; Meng, X.; Sun, D. Review of Automotive Thermoelectric Generator Structure Design and Optimization for Performance Enhancement. Processes 2025, 13, 1931. https://doi.org/10.3390/pr13061931

AMA Style

Wang Y, Wang R, Chai R, Ding R, Ye Q, Sun Z, Meng X, Sun D. Review of Automotive Thermoelectric Generator Structure Design and Optimization for Performance Enhancement. Processes. 2025; 13(6):1931. https://doi.org/10.3390/pr13061931

Chicago/Turabian Style

Wang, Yue, Ruochen Wang, Ruiqian Chai, Renkai Ding, Qing Ye, Zeyu Sun, Xiangpeng Meng, and Dong Sun. 2025. "Review of Automotive Thermoelectric Generator Structure Design and Optimization for Performance Enhancement" Processes 13, no. 6: 1931. https://doi.org/10.3390/pr13061931

APA Style

Wang, Y., Wang, R., Chai, R., Ding, R., Ye, Q., Sun, Z., Meng, X., & Sun, D. (2025). Review of Automotive Thermoelectric Generator Structure Design and Optimization for Performance Enhancement. Processes, 13(6), 1931. https://doi.org/10.3390/pr13061931

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