ME 423 Engineering Design VII

Thermoelectric Cell Phone Charger

A Senior Report: Phase III Engineering Design

Group 34

Gary Aramini
Ryan Charterina
Lloyd Clave
Mark Glindmeyer
John Rotsides

Advisor

STEVENS INSTITUTE OF TECHNOLOGY

CASTLE POINT ON HUDSON
Hoboken, NJ 07030
12.09.14

Dr. Yong Shi

Contents
Abstract: .......................................................................................................................................... 1
Introduction: ................................................................................................................................... 1
Project Objectives: ...................................................................................................................... 1
Project Background: .................................................................................................................... 1
Feedback from Phase I and II: ..................................................................................................... 2
Physical Design: ............................................................................................................................... 2
Heat Source: ................................................................................................................................ 3
Thermal Housing: ........................................................................................................................ 3
Electrical Design: ............................................................................................................................. 6
DAQ: ............................................................................................................................................ 6
Voltage Regulator:....................................................................................................................... 6
Complete Circuitry: ..................................................................................................................... 7
Mathematical Modeling and Analysis: ........................................................................................... 7
Bill of Materials and Budget............................................................................................................ 9
Project Schedule: .......................................................................................................................... 10
Societal, Environmental, Health, and Safety Impact: ................................................................... 11
Conclusion: .................................................................................................................................... 11
Summary: .................................................................................................................................. 11
Next Steps: ................................................................................................................................ 11
Appendix: ..................................................................................................................................... A-1
Thermal Calculations: ............................................................................................................... A-1
Engineering Drawings:.............................................................................................................. A-4
Base....................................................................................................................................... A-4
Pot ......................................................................................................................................... A-5
Lid ......................................................................................................................................... A-6
Handle ................................................................................................................................... A-7
Insulating Layer ..................................................................................................................... A-8
Exploded View & Bill of Materials ........................................................................................ A-9

Abstract:
In order to demonstrate the concept of energy conversion, a device will be designed and
constructed to explore its applications. The specific aspect of energy conversion explored in
this project is the thermoelectric effect; this is the conversion from thermal energy into
electrical energy. To accomplish this, a temperature difference must occur via a controlled heat
source, which can then be converted into a voltage difference, therefore creating an electric
current. This is the same technology that allows thermocouples to work. After much research,
it was found that enough thermal energy from a small portable source, such as a butane torch
or a chafing fuel, could be created in order to generate sufficient electricity to charge a cell
phone or comparable electronic device. This type of device could be used in emergency
situations where power is unavailable, or in recreational activities such as camping and hiking.

Introduction:
Project Objectives:
The goal of this project is to incorporate existing thermoelectric technology in the
design of a safe, portable and efficient phone charger for use in emergency situations. The
Seebeck effect will be utilized to convert thermal energy into electricity that will be able to
charge a phone.

Project Background:
Cell phones and smartphones have now become part of our everyday lives. With
smartphones continuously increasing with their capabilities, they are no longer only used just to
make phone calls. Users can take pictures, send emails, play games, surf the web, or even use it
to control appliances at home. Most people use their phones throughout the day causing large
battery consumption. Consequently, users must constantly search for a source of electricity.
Unfortunately, electricity may not always be available everywhere at any time. For example, a
traveler or a camper would have a difficult time searching for an outlet in the forest. Power
outages can occur frequently due to extreme weather as well as transmission and distribution
problems. It may also be possible that an electrical power source is just not conveniently
available to the public. This project will increase the availability of electricity by using another
source of energy heat. The team will design and build a portable and safe device that will be
able to charge a mobile phone using heat. This device will allow people to not only rely on
electricity for power but also give the capability of charging a phone anywhere as long as heat is
available. Such a device will be extremely useful in a time of emergency when electricity is not
available.
The charging device will use the Seebeck effect of thermoelectric materials. The Seebeck
effect is named after the Baltic German physicist Thomas Johann Seebeck, who discovered the
concept in 1821. Seebeck originally discovered that if a copper strip was joined to a strip of
bismuth to form a closed circuit, a current would be induced if one junction was heated and
1

there was a temperature difference. The Seebeck effect is a phenomenon in which a

temperature difference between two dissimilar electrical conductors or semiconductors
produces a voltage difference between the two substances. When heat is applied to one
conductor, electrons flow towards the cooler one and with an electric circuit connected, direct
current is able to flow through the circuit. Using temperature differences and the transfer of
heat it is possible to generate a current of electricity. This current of electricity can then be
used to power up the mobile phone.
Major concerns for the team will include designing the product for portability. The
product must be small enough to be able to carry comfortably in an average backpack. The
product must also be safe. Possible heat sources for this project include a butane lighter or a
small fire. There will be a safety concern using these indoors, near an electrical device, or even
a battery. Finally the thermoelectric charging device must be able to provide enough energy to
be viable as a charger for a cell phone. Since the design will be small, creating enough voltage
to provide energy for a mobile phone may be an issue.
Users of this device will have many different requirements in order to make the device
attractive for use. Some of these needs include portability, ease of use, and safety for the user.
These customer needs were analyzed and ranked by their importance. These needs, along with
their corresponding metrics, define the initial design requirements.

Feedback from Phase I and II:

In Phase I, the team presented the overall concept for the project. The feedback that
was given to the team was: The team needed to identify a clear and concise goal, and to focus
the design comparisons on the entire design of the product rather than one small aspect. In
addressing these problems, the group moved forward by developing a clear application for this
particular device. The application for this project is for emergency use, and steers the scope of
the project in this direction. As for the design comparisons, the team came up with three
different designs that were compared with specific criteria that the team determined.
For phase II, the group received feedback in the following areas: the range of
temperatures needed to be reconsidered based on Figure 4: Boiling Point Chart and the team
learned after a brief discussion with the panel that a diode would be unnecessary because the
voltage regulator has a diode within itself. In addressing this feedback, the group adjusted the
thermal calculations to lower the maximum temperature, to keep the temperature lower than
Point C in Figure 4: Boiling Point Chart.

Physical Design:
Following concept generation and concept screening, the group generated a more
detailed design for a thermoelectric cell phone charger. The concept that the group decided to
move forward with is a pot for boiling water placed above the thermoelectric generators. Below
the pot is a base for housing of the thermoelectric generators.
2

Figure 1: Selected Concept

Boiling water over the heat source has key benefits. First, the heat input and the hot and
cold side temperatures of the TEG are controlled. The heat input is controlled because the pot
is designed for compatibility with heat sources with adjustable flames such as a gas stove and
camp stove. The cold side temperature of the TEG faces the boiling water. Since water boils at a
constant 100C, the cold side of the TEG will remain close to 100C, proven in the thermal
analysis of the system. The hot side temperature of the TEG varies directly with the heat input.
Since the heat input is controlled, the hot side temperature is controlled as well. The user will
increase or decrease the heat input based on feedback from the system.
Boiling water introduces secondary functions for the product such as providing the user
with potable water in emergency situations and allowing the user to cook food while charging
his/her cell phone.

Heat Source:
The group chose to focus the product on being used in emergency situations. The main
heat source chosen to produce the thermal energy was gas-powered stoves. Using gas stoves
allows the user to adjust the heat flux into the system, which helps keep the system at a more
uniform temperature. The group plans to provide feedback to the user in order to instruct the
user when to increase or decrease the amount of heat being applied to the system. This will
both prevent overheating and also increase efficiency.

Thermal Housing:
The bulk of the product is the thermal housing. The thermal housing includes the base,
insulating layer, thermoelectric generators (and associated wiring), pot, and lid with handle.
Each component can be viewed as a conductive layer with a corresponding thermal resistance.
3

Designing the thermoelectric cell phone charger as various conductive layers allows for
accurate heat transfer calculations because conductive heat transfer modeling techniques are
well-established.

Figure 2: Thermal Housing

The base is a round component made of stainless steel. It serves as housing for the
insulating layer as well as the thermoelectric generators. There is a cut-out in the base that
matches the shape of four thermoelectric generators in a square arrangement. The cut-out
includes additional space for the wires of the thermoelectric generators as they are connected
in series. A slot for the output positive and negative wires of the TEG extends to the OD of the
base, allowing room for wires to come out of the device. The OD of the base is influenced by
the size of the TEG.
The insulating layer is made of fiberglass. This component provides insulation for the
TEG and associated wiring. Implementing an insulating layer allows the user to input a greater
amount of heat without exposing the TEG to unsafe temperatures (i.e. exceeding 320C). This
translates to allowing for a greater potential for power generation while protecting electronic
components. The shape of the insulating layer matches the cut-out in the base of the device for
easy placement.
The TEG is comprised of four thermoelectric modules connected in series, forming a
square. Each module is 40x40mm, causing the TEG to be an 80x80mm square. The design
implements four thermoelectric modules as a result of the thermal analysis of the system. The
resultant temperature difference of the thermal analysis proves that four modules are
necessary in order to generate enough power to charge for a cell phone, with losses taken into
account.

Figure 3: TEG Housing

The pot is another round component made of stainless steel. It interfaces directly with
the base and is secured via magnets for quick assembly/disassembly. The pot can be filled with
up to 1 liter of water for boiling. A stainless steel lid with welded handle is included to rest on
top of the pot. The purpose of including a lid is to reduce the evaporation of water so the user
doesnt need to replace the water as frequently.
The protection of the wires is a critical part of this project. Although it is a small part,
the wires are what transfer the electrical energy within the modules to the phone. Because the
wiring is dangerously close to the heat source, the team needs to find a solution to insulating
the wiring to prevent them from melting.
In finding an applicable thermal insulation tape, the team identified the factors in
determining which tape is necessary. The team found a fiberglass color coded woven tape,
which can withstand temperatures up to 593C in continuous service. The hot side of the TEG
cannot exceed this temperature, so the team chose this thermal tape. This tape is only
available in 1/16 thickness, but the group concluded that this thickness would be enough for
its application. Another benefit of the selected tape is that this company sells the tape in
increments less than 100 feet, which would be excessive for the teams needs. The team can
select between lengths of fifteen feet, twenty-five feet and fifty feet. Also, this company
provides for a width of one and two inches in width.
One of the main concerns the group had when designing the product was ensuring that
the thermoelectric modules did not overheat. The modules have a very specific maximum
temperature, that when exceeded, results in immediate failure of the module. In order to
5

prevent this from happening, the group chose to add an insulating layer between the heat
source and the thermoelectric modules. Fiberglass was chosen as the insulating layer for its
excellent insulating qualities.

Electrical Design:
DAQ:
Data acquisition (DAQ) is the process of measuring an electrical or physical phenomenon
such as voltage, current, temperature, pressure, or sound and converting the resulting samples
into digital numeric values that can be manipulated by a computer. DAQ systems typically
convert analog waveforms into digital values for processing. Data acquisition systems include
the following components: sensors that measures and converts physical parameters to
electrical signals, signal conditioning circuitry, analog-to-digital converter (ADC), and a
computer bus. DAQ hardware acts as the interface between a computer and signals from the
outside world. The DAQ applications are typically controlled using general purpose
programming languages such as LabVIEW.
The design will include two thermocouples that will be placed on each side of the TEG
module. These thermocouples will keep track of the hot side temperature and the cold side
temperature. The thermocouples will then be connected to the DAQ so it is able to process and
sample the temperature data into readable data. The DAQ will then provide feedback to
indicate if the temperatures are becoming too hot or too cold. This will allow the group to know
whether to increase the flame on the stove or to decrease it. There will be a necessary
temperature differential between the hot and cold sides of the TEG module in order to achieve
the most efficient electrical output and charge. Using a DAQ system will provide feedback to
help control the efficiency and charge rate of the product. The group plans to use a DAQ
module that is able to provide feedback on the thermocouples and voltage of the circuit. This
module will be used only for testing purposes and will help the group optimize the product.

Voltage Regulator:
The group decided to incorporate a voltage regulator in the circuit design because the
group needed a way to take the power output from the TEG modules and produce the required
power to the USB port to charge the phone. The two voltage regulators the group are looking in
to incorporating are the 7805 5V Fixed Voltage Regulator and the NTE961 Voltage Regulator
(both seen below). A voltage regulator contains a built in diode. The function of this diode is to
make sure that the current only flows forward from the TEGs to the regulator and then from
the regulator to the USB port. A backwards flow of current would cause the power from the
phone to cool down the TEG modules, which is undesired. A phone requires 5 volts and 1 amp
in order to charge. Producing a voltage over 5 volts can damage the phone. To solve this
problem, the group implemented a voltage regulator. The voltage regulator will take the output
6

from the TEG modules and regulate the voltage to only allow 5 volts to be sent to the phone.
This will avoid the possibility of damaging the phone while charging.
The only drawback is that the voltage regulator has a dropout voltage. Dropout voltage
is a loss in voltage between the input and output of the regulator. To account for the loss in
voltage, it is necessary to produce more power from the TEG modules. Without the regulator,
the TEG would only need to produce 5 watts of power in order to charge the phone, but if more
power is produced there is a risk of damaging the phone. The voltage regulators under
consideration both have a dropout voltage of .5 volts, a relatively low dropout. The TEGs need
to produce a minimum of 5.5 volts in order to achieve a regulator output voltage of 5 volts.
Implementing the voltage regulator eliminates the risk of damaging the phone at the cost of
requiring a minor increase in power generation.
A production of power over 5.5 volts presents another potential problem. If more power
is produced and sent to the voltage regulator, the excess power will be lost in heat in the
regulator. A heat sink may be attached to the voltage regulator in order to dissipate additional
heat, avoiding damage to the voltage regulator.

Complete Circuitry:
The group is going to create a relatively simple circuit for the power to flow to the
phone. The TEG modules will produce the power and will be attached to a 5 volt voltage
regulator. This voltage regulator will take the power produced and regulate it so that only 5
volts (maximum voltage to charge a phone without damaging it) can pass.Excess power will be
transformed and released as heat from the voltage regulator. The voltage regulator will then
connect to a USB port where the phone charging cable will attach. This whole circuit assembly
will be enclosed in a small box with a protective strip around the wiring to avoid any damage if
it gets too close to the pot or flame.

Mathematical Modeling and Analysis:

The group was able to perform an analytical analysis on the system in order to get a
better idea of how the system will react to different heat inputs. This analysis utilized a
program created by the group in Mathematica. This allowed for variables to be changed easily
in order to see how the system reacts in different scenarios. The first section of the program
(see Figure 7: Thermal Calculations in the appendix) defines all of the known constants in the
system. This includes all of the thermal conductivities, dimensions, minimum and maximum
temperature of the inner kettle wall, and the minimum and maximum heat flux into the system.
The minimum and maximum inner kettle wall temperatures were found from Figure 4 found in
Heat and Mass Transfer: Fundamentals and Applications. The group chose to keep the
temperature between points A and C on the chart in order to avoid any unpredictability, and to
7

ensure the safety of the thermoelectric modules. The minimum and maximum heat flux were
assumed values that the group felt was a reasonable estimated range of heat flux values from
an average gas stove.

Figure 4: Boiling Point Chart

The next section of the program handled all of the calculations. In order to find the
temperature difference a thermal resistance network was used. This network can be seen in
Figure 5 below. As seen below, the analysis was preformed from the water to the
thermoelectric modules, this method was chosen due to the number of known or controlled
variables on that side on the model. The first set of calculations dealt with the resistances for
each individual material in the resistor network. The thermoelectric module needed to be
broken up into three sections: two ceramic sections and a center section, which was assumed
to be made up of entirely bismuth-telluride. This was a fair assumption, which significantly
simplified the calculations. After the resistances were calculated, the minimum, maximum
temperature for each side of the thermoelectric module, and temperature differences could be
calculated. From these calculations, the temperature difference range was found to be
between approximately 15 and 60 F.

Figure 5: Thermal Resistance Network

Bill of Materials and Budget

The bill of materials was an important aspect to the groups success. This planning
allowed the group to better organize what materials needed to be purchased and how much
they would cost. This also allowed the group to avoid going over budget and to keep track of
their spending in an organized way. The most important, and expensive, aspect of the system
was the thermoelectric module. When choosing the correct thermoelectric module the group
was not concerned with price, however the group was very concerned with performance and
efficiency. The group chose to go with the TEG1B-12610-5.1 sold by Tecteg. This was the most
efficient and appropriate choice for our application. The unit price for the TEG is $40 and the
group planned to buy four of them, which added up to a total of $160.
The group conducted research to pick out the best voltage regulator for the projects
purposes. The group learned that the worst voltage regulators had an accuracy of 5%. With this,
most voltage regulators would suffice for the project. Most voltage regulators only cost a few
dollars so price was not a big aspect. The most important considerations for purchasing a
regulator were availability, its output voltage, which had to be 5 volts, and its dropout voltage,
which dictated the minimum loss needed to achieve the 5 volts. The group chose and ordered
the 7805 5V Voltage Regulator and the NTE961 Voltage Regulator, both of which produced 5
volts with a dropout voltage of 0.5 volts.

Component
Base
Insulating Layer
Pot
Lid
Handle
Thermoelectric Generator
Wiring
Voltage Regulator
Insulating Tape
USB Port
Thermocouple

Unit

Unit Price ($/Unit)

Quantity Price

kg
in2

$5.11
$0.02

1.37
14.22

$7.00
$0.28

kg
kg
kg
each
ft
each
each
each
each

$5.11
$5.11
$5.11
$40.00
$0.21
$5.00
$11.00
$2.00
$20.00

1.21
0.662
0.0024
4
10
1
1
1
2

$6.18
$3.38
$0.01
$160.00
$2.08
$5.00
$11.00
$2.00
$40.00

TOTAL

$236.95

Figure 6: Project Budget

Project Schedule:
During phase I, a Gantt chart was created in order to come up with a plan, schedule, and
deadlines for the design project. This Gantt chart allowed the group to keep track of their
progress and milestones. The group followed the schedule very closely and accurately. All
deadlines and tasks were met successfully on time. Heavy early brainstorming and background
researching was completed during Phase I for the report and presentation. The group was able
to learn much about thermoelectric modules, how they work, and the amount of electrical
power they can produce. During Phase II, initial modelling and simulation was completed. The
group also continued their research on thermoelectric products and various electrical
components. Phase II allowed the group to work on the feasibility of several physical designs
until they agreed on a kettle design to be the best. The group has been finalizing the design and
working on the specific details for Phase III in order to prepare and move forward to the next
phases.
Phases IV, V, and VI will be carried out next semester. The complete list of parts and
materials needed to build the design project will first be completed. These will all be ordered
right away in order to proceed with building the initial prototype. A specific plan for tests will
be created and extensive testing will be carried on throughout the next semester. This will
allow the group to make adjustments for a better overall product. After final testing, all
specifications would be finalized with the final prototype completed.

10

Societal, Environmental, Health, and Safety Impact:

This product will have an impact on more aspects than the immediate stakeholders
involved. It will be available to everyone as long as the user has a gas stove. This product will
also have a negligible environmental impact because there are low emissions associated with
the combustion of the fuel source. The group will be using a gas stove to heat the water to a
boil, but this will have no more impact than the everyday use of said gas stove.
One major area of impact this product will have is socially. If a transformer goes down
or a disaster strikes and power to the consumers home is lost, this product will offer the ability
to charge the consumers cell phone and stay in contact with the outside world. In the event of
a natural disaster, it will allow the consumer to contact family members or call for help.
In regards to health and safety, this product offers a high degree of safety. The user
simply boils water during the charging process. It is no riskier to boil water with the device than
when a user would normally do so. The user is not exposed to any harmful chemicals or highrisk scenarios when using the device. The only risk associated is the possibility of the user
touching the hot metal pot during use. However, this is the case for any other cooking
appliance.

Conclusion:
Summary:
The goal of this project is to incorporate existing thermoelectric technology in the
design of a safe, portable, and efficient phone charger for use in emergency situations. This
project will allow users to no longer only rely on an electrical source for energy to charge their
mobile device. This portable charging device will allow a user to have another option of
obtaining energy using heat. A thermal source such as a campfire or a stove will be sufficient to
provide energy to your phone.
The group will now be finalizing and reviewing the detailed physical design. Moving
forward into the next semester, all necessary parts will be ordered as soon as possible. The
group will start planning test methods and strategies in order to optimize and make
adjustments for an improved product. The group is ready to start building their prototype in the
coming semester. This product has much potential and is tailored to be a great option when
electricity is not available.

Next Steps:

Reviewing finalized physical design for product

Finalizing list of necessary parts and materials
Ordering all necessary items
Begin building prototype
Plan and create testing methods and schedule
11

Appendix:
Thermal Calculations:

A-1

A-2

Figure 7: Thermal Calculations

A-3

Engineering Drawings:
Base

Figure 8: Base

A-4

Pot

Figure 9: Pot

A-5

Lid

Figure 10: Lid

A-6

Handle

Figure 11: Handle

A-7

Insulating Layer

Figure 12: Insulating Layer

A-8

Exploded View & Bill of Materials

4
3

2
5
1

Figure 13: Exploded View & Bill of Materials

A-9