RESEARCH PROGRESS ON THE CO-DESIGN OF HIGH-EFFICIENCY THERMOELECTRIC CONVERSION MATERIALS AND MECHANICAL SYSTEMS: FROM PERFORMANCE MATCHING TO ENGINEERING APPLICATIONS

Abstract

This study presents a comprehensive investigation into the co-design of high-efficiency thermoelectric conversion materials and mechanical systems, focusing on performance matching and engineering applications. A mixed-methods approach integrated qualitative synthesis of literature (2018–2022), quantitative modeling, and finite-element simulations to evaluate the interplay between material performance and mechanical integrity. The analysis revealed that high-entropy alloys, nanostructured composites, and hierarchical architectures significantly improved Seebeck coefficients, reduced lattice thermal conductivity, and enhanced power factors, resulting in thermoelectric figures of merit (zTzTzT) exceeding conventional benchmarks. Tables demonstrated consistent eigenvalue distributions, spectral decompositions, and density matrix approximations that quantified these gains across varied operating conditions. Figures 2–13 provided detailed visualizations of electrical conductivity distributions, stress mapping under temperature gradients, and hybrid plots correlating power density with zTzTzT trends, confirming the robustness of co-designed systems under thermal cycling.

Mechanical system innovations, including compliant buffer layers, optimized heat-sink geometries, and flexible substrates, mitigated thermal stress and improved module lifetime, as validated by scatter and hybrid plots depicting clustering of stress distributions. Performance matching between peak material properties and module design parameters achieved superior energy conversion efficiencies across simulated automotive, aerospace, and wearable applications. The integration of adaptive control strategies further optimized heat flux alignment, reducing losses and increasing long-term reliability. These findings collectively establish co-design as a transformative paradigm that unites material science, mechanical engineering, and sustainability. By emphasizing iterative feedback between material development and mechanical configuration, the study offers a scalable framework for advancing thermoelectric technology toward real-world energy harvesting and thermal management solutions.