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The construction and evaluation of wholly skutterudite thermoelectric modules with a high volume-power-density is described. Such modules afford the maximum power output for the minimum use of material. Synthesis of the component n type unfilled skutterudite CoS132.75Sno.osTe0.20 and p-type filled skutterudite Ce0.5Ybo.sFe325Co0.75Sb12 was achieved using a scalable ball-milling route that provides sufficient material for the construction and assessment of performance of 12 modules. Impedance spectroscopy at room temperature is shown to provide a rapid means of evaluating the quality of module fabrication. The results show a high degree of reproducibility in module performance across the 12 modules, with an average internal resistance of 102(4) mat. Electrical measurements on the component n- and p-type materials reveal power factors (S2 I p) of 1.92 and 1.33 mW m(-1) K-2, respectively, at room temperature and maximum figures of merit of ZT = 1.13 (n-type) and ZT = 0.91 (p-type) at 673 and 823 K, respectively. The figure of merit of the module at room temperature (ZT = 0.12) is reduced by ca. 39% from the average of the n- and p-type component materials at the same temperature, as a result of thermal- and electrical-contact resistance losses associated with the architecture of the module. I V curves for the module determined for AT in the range 50-450 K show an almost linear dependence of the open-circuit voltage on AT and allow calculation of the power output, which reaches a maximum value of 1.8 W (0.9 W cm(-2)) at AT = 448 K.

Skutterudite Thermoelectric Modules with High Volume-Power-Density: Scalability and Reproducibility