Thomson Effect, Leg Design, Heat Interaction, and Material Impacts on Segmented Thermoelectric Cooler: Insights From Three-Dimensional Simulation

Abstract Thermoelectric coolers (TECs) have emerged as promising cooling solutions; however, their relatively low coefficient of performance (COP) remains challenging. Hence, to better understand the factors influencing TEC efficiency and to guide the design of more effective systems, a three-dimensional numerical model is developed. It includes temperature-dependent thermoelectric properties (Thomson effect) and convective–radiative heat interactions. This study explores the TEC performance by analyzing various leg configurations, such as segmented and non-segmented legs, with constant and variable cross section using different material compositions to maximize the cooling effect and COP. Cylindrical legs outperformed conventional square legs, offering a 3% increase in COP and 2.5% in cooling effect. The non-segmented legs emphasize the need for condition-specific material selection, while segmented legs show up to 6.3% higher COP and 5.5% better cooling effect at lower currents, with performance declining at higher currents. A larger temperature lift between the hot and cold sides reduces TEC efficiency. The material-specific segmented leg length ratio can be optimized for maximum performance. A uniform circular leg cross section is more effective than a variable one. Incorporating the temperature-dependent material properties and the Thomson effect in the model significantly increases the TEC performance (up to 30%). Similarly, considering convective–radiative heat interaction in the model increases the performance (about 10%). These two inclusions enhance the accuracy of performance prediction of the model used in this study. These findings provide valuable insights for designing TECs according to application and operating conditions.