Study on the performance of thermoelectric generator with topology-optimized heat sinks

This study proposes a three-dimensional topology optimization strategy for the structural design of passive cooling heat sinks in thermoelectric generator (TEG)-based waste heat recovery systems. The optimization objective focuses on minimizing the average temperature on the cold side of the TEG, thereby enhancing natural convection cooling and improving the power output and conversion efficiency of the system. The results demonstrate that the topology-optimized heat sink enhances natural convection by promoting interaction between the fins and airflow, significantly reducing the average temperature on the cold side of the TEG and improving the system's thermoelectric performance. Quantitatively, the 3D topology-optimized heat sink outperforms conventional straight-fin designs, increasing output power by 27.9 % and thermoelectric conversion efficiency by 14.5 %. Furthermore, flow field analysis using the Q -criterion reveals enhanced vortex structures and airflow mixing, contributing to superior convective heat dissipation. These findings confirm the effectiveness of 3D topology optimization in improving both the cooling performance and energy conversion efficiency of TEG-based waste heat recovery systems.