Design of zonal air-to-liquid thermoelectric cooling system for electric vehicles: Optimization and performance evaluation

• Zonal TEC system for EVs achieves 1000 W cooling with 12 thermoelectric modules. • Experimental prototype surpasses COP predictions, reaching 1.09 at 19.9 °C outlet. • Refrigerant-free cooling design offers modular, scalable EV thermal management solution. • Dimensional analysis optimizes TEC performance through precise current and geometry. • Advanced material properties model accounts for real-world thermal and electrical losses. This study explores the design, optimization, and performance evaluation of a zonal air-to-liquid thermoelectric cooling (TEC) system for electric vehicles (EVs). The system integrates thermoelectric modules, aluminum heat sinks, and liquid heat exchangers to deliver energy-efficient thermal management and enhanced passenger comfort. A dimensional analysis and optimization framework was developed to maximize cooling capacity and coefficient of performance (COP). Effective material properties were incorporated to address real-world factors such as thermal resistance and contact losses. A prototype comprising 12 TEC modules achieved a cooling capacity of 1000 W, with experimental validation revealing strong alignment with predicted results. Minor discrepancies, attributed to frictional losses, measurement uncertainty, and real-world conditions, were observed. The experimental system achieved a COP of 1.09, surpassing the predicted value of 0.9, and reduced cold air outlet temperatures to 19.9 °C. Comparative analysis highlighted an optimal balance between cooling power and energy efficiency at specific conductance and current values. The system's modularity, scalability, and use of refrigerant-free technology offer a sustainable alternative to conventional vapor-compression cooling systems. These findings demonstrate the potential of thermoelectric cooling for automotive applications, advancing the field of EV thermal management while contributing to global energy efficiency and sustainability goals.