Phase 3

Phase 3 was the beginning of prototype development for the team. Using reference research, the group attempted to fabricate the thermoelectric generators using molds, Bismuth Telluride powder, Antimony Telluride powder, curing agents, copper paste, and more.

12/2/19- Start of Experimentation

On December 2nd, the team received their cardboard and metal molds from the machine shop to be used to start experimentation.  There were slight delays with the machine shop, so the group unfortunately did not receive their bottom metal mold.  Both are shown below:

The group began using the metal mold to place the n-type and p-type semi-conductor pastes onto a substrate to form the thermoelectric (TE) legs.  Glass fabric was then placed on top before creating a second set of legs.  After allowing the pastes to dry and removing the molds, the group quickly realized that the metal mold was not working as anticipated, and had to begin to create a new method of producing the TE legs.  This was one of many challenges that occurred for the team as they begun prototyping. 

12/9/19- Continuation of Experimentation

Over the week after beginning initial prototyping attempts, the group tried various methods of creating the TE legs. The first change was utilizing PDMS for the molds instead of metal.  The PDMS allowed more freedom in removing the mold and didn't cause the paste for the legs to get stuck as much.  The various molds used are shown below. There were three different designs- one to be peeled off, one with small slits, and one completely cut in half. 

Overall, the group was still working on an effective method that produces the TE legs with the desired results.  The group was also waiting for other materials to arrive such as copper paste, to connect the TE legs to each other.  Once the group is able to make sufficient TE legs, they can be annealed in the lab's oven, shown below.  For bigger samples, the group will have to utilize the Micro Device Lab here at Stevens.  

The group has faced many challenges during Phase 3 and they tried to create their initial prototype but they are looking forward to having a new and efficient procedure to continue making the device. 

12/10/19 - Phase 3 Report

On December 3, completed their Phase 3 report detailing all of their experimentation conducted thus far. This included all of the mold testing, TE leg fabrication, assembly, and a testing and evaluation plan as they moved into Phase 4.

12/12/19 - Phase 3 Presentation

On December 12, the group presented their Phase 3 alpha prototype progress to a panel of Stevens administration and peers. In this presentation, they highlighted the main accomplishments from this phase as well as their plan for Phase 4's beta prototype.

Moving into Phase 4, the team's main goals are to conduct more fabrication and experimentation on the TEG with hopes of having working thermoelectric legs to move on with and continue the fabrication process.