The current efforts of design optimization, including load resistance, topology, and parasitic energy loss analysis, mainly focus on the thermoelectric modules operating under constant temperature difference. By contrast, these mechanisms contribute to the output parameters of thermoelectric modules under constant heat flux is still ambiguous. Here, by choosing the PbTe as a case study, COMSOL Multiphysics software to establish the three-dimensional numerical model is employed. The quantitative analytical method for heat transfer verifies that the reduction in hot side temperature of modules is dominated by Peltier effect, leading to the deviation of practical optimal ratio between load resistance and internal resistance (RL/Rin) from the traditional maximum power point (MPP). Moreover, the increased thermoelectric leg height significantly enhances the average figure of merit zTavg of P/N thermoelectric materials, triggering an improvement of optimal RL/Rin and output performance. Through manipulating the leg cross-sectional area ratio (Ap/An) to ∼0.82, a high efficiency of ∼14.5% is achieved for ideal contacted PbTe-based thermoelectric modules at a temperature difference of 500 K. Furthermore, the critical role of parasitic energy loss on performance evolution are recognized. Eventually, the different types of module are established to verify the effectiveness of above theory. The present findings provide universal guidance for advancing the efficiency of thermoelectric modules operating under constant heat flux.
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