Work

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

Year: 2025

Type: article

Abstract: • 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.

Source: Results in Engineering

DOI: 10.1016/j.rineng.2025.104803

Author: Alaa Attar

Institution: King Abdulaziz University

Language: English

Topic: Advanced Thermoelectric Materials and Devices

Subfield: Materials Chemistry

Field: Materials Science

Domain: Physical Sciences

SDGs: Affordable and clean energy, Industry, innovation and infrastructure

Open Access status: gold

Estimated APC paid: $1,940