Thermoelectric
generators have found many applications where the
heat source can be either flat or curved. For a curved heat source,
flexible thermoelectric generators are generally used. A filler material
with low thermal conductivity can provide additional mechanical support
to the thermoelectric module and can reduce convection and radiation
losses. Herein, the effect of three different filler materials on
the output performance of rigid and flexible thermoelectric generators
is investigated. At first, theoretical models are derived and the
experimental study validated the models. The experimental study revealed
that the flexible thermoelectric modules outperformed the rigid modules;
this is due to the reduction of the number of thermal junctions in
the flexible modules and due to the differences in the thermal conductivities
of the flexible and rigid substrates. Likewise, among TE modules without
filler/with air between the TE legs, with polyurethane foam filler
material, and with polydimethylsiloxane filler material, air has the
lowest thermal conductivity, and therefore, the thermoelectric generator
without filler generates higher output power and higher power density
than when the other two filler materials are used. For the fixed temperature
gradient, the highest power densities for the flexible and rigid thermoelectric
generators without filler are 155 and 137.7 μW/cm2 for temperature gradients of 10.8 and 10.3 °C, respectively.