Integrated design and optimization of a heat pipe-based thermoelectric generator for range-extended electric vehicles

Thermoelectric generation offers a promising solution for converting exhaust waste heat into electrical energy, thereby extending the driving range of range-extended electric vehicles. To enhance power output within limited space, this study proposes a novel thermoelectric generator structure integrated with heat pipes. The finned heat pipes are arranged perpendicular to the exhaust flow to improve heat collection efficiency. A numerical optimization is conducted to determine the optimal heat pipe length and quantity based on the maximum net output power. Results indicate that increasing the heat pipe length enhances heat transfer but also leads to greater pressure loss, while increasing the number of heat pipes improves output power up to a saturation point. The maximum net power output of 154.19 W is achieved when the heat pipe length is 30 mm and the number of heat pipes is six. This work provides an effective design strategy for improving thermal energy recovery in range-extended electric vehicles.