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In this work, computational modelling and performance assessment of several different types of variable thermoelectric legs have been performed under steady-state conditions and the results reviewed. The study conducted has covered geometries, not previously analysed in the literature, such as Cone-leg and Diamond-leg, based on the corresponding thermoelectric generator leg shape structure. According to the findings, it has been demonstrated that the inclusion of a variable cross-section can have an impact on the efficiency of a thermoelectric generator. It has been concluded that the Diamond configuration generated a slightly larger voltage difference than the conventional Rectangular geometry. In addition, for two cases, Rectangular and Diamond configurations, the voltage generated by a TEG module consisting of 128 pairs of legs was analysed. As thermal stress analysis is an important factor in the selection of TEG leg geometries, it was observed based on simulations that the newly implemented Diamond-leg geometry encountered lower thermal stresses than the traditional Rectangular model, while the Cone-shape may fail structurally before the other TEG models. The proposed methodology, taking into account the results of the simulation carried out, provides guidance for the development of thermoelectric modules with different forms of variable leg geometry.

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