Thermo Electric Trace, Power at Pace: Optimization of Power Output in Seebeck Mode Peltier Modules through Enhanced Thermal Paste and Heat Sink Design

The increasing demand for efficient waste-heat recovery systems highlights the need for optimized thermoelectric generators (TEGs). This study investigates the enhancement of power output in Peltier modules operating in Seebeck mode by focusing on the synergy between thermal interface materials and heat sink configurations. Using a mixed method convergent parallel design, the research simultaneously gathered quantitative experimental data and qualitative observational data to provide a holistic understanding of thermal management efficiency. In the quantitative research, an experimental approach was used to measure voltage, current, and wattage outputs across three different thermal paste formulations and heat sink.

Parallel qualitative observations during the "Cooling Efficiency" and "Stability" tests provided context for these numerical drops, identifying thermal saturation and "pump-out" as primary limiting factors. The merging of data confirmed that peak efficiency is not reached through maximum cooling or maximum material application, but through an optimal thermal "middle ground." These findings provide a scalable framework for improving waste-heat recovery systems in small-scale green technology. Observations of the "Cooling Efficiency Test" revealed that the removal of cooling agents led to a voltage drop to 0.15V, confirming that the system’s "Power at Pace" is dependent on maintaining a sharp thermal gradient rather than just cooling. The data suggests that excessive paste acts as a thermal insulator (pump-out effect), while the heat sink’s capacity limits long-term peak performance. The study concludes that an optimized "middle-ground" approach in material application is superior for small-scale thermoelectric energy harvesting.