Design of linear shaped thermoelectric generator and self-integration using shape memory alloy

•The linear-shaped thermoelectric (TE) module based on higher specific figure-of-merit is proposed by using Cu–AlN electrode.•The specific power density [W/kg] of the linear shaped TE generator is higher than that of the π-shaped TE generator.•New integration method using Fe based shape memory alloy and shrink-fit mechanism is developed for secure fastening.

A segmented linear-shaped thermoelectric generator was designed with n-type Mg2Si and p-type higher manganese silicide as higher temperature segments and n-type and p-type Bi–Te based compounds as low temperature legs. A new design of a dovetail-shaped AlN–Cu composite as an electrode enabled linear-shaped thermoelectric generator to be securely bonded to the combustion chamber walls by using shrink-fit-joining method. As-assembled linear thermoelectric generator is lighter in generating more power output as compared with conventional π-shaped thermoelectric generator. The linear thermoelectric module generates the output power of 0.513 W under 500 °C temperature difference and the specific power density was measured at 89.3 W/kg, the output power was improved by 7% and the specific power density more than 2 times, as compared with those of the π-shaped thermoelectric module based on the same set of thermoelectric materials and temperature differential.