The Thermovore: A Novel Thermoelectric Generator Design to Convert Wasted Heat into Energy

Overview

Every day, vast amounts of usable energy escape into the air as low-grade waste heat from pipes, ducts, engines, and building systems. This energy is largely ignored because the only way to harvest this waste heat is by using existing thermoelectric generators (TEGs) which are rigid, have a limited application and are expensive to produce and use hazardous materials. This project addresses that engineering gap through the design, fabrication, and optimization of a flexible thermoelectric generator prototype, specifically engineered for conformal heat harvesting. My invention is named “The Thermovore” and it operates using the Seebeck effect, where a temperature difference across dissimilar thermoelectric materials causes charge carriers to move, generating an electrical voltage. A modular flexible TEG architecture was developed using commonly available metals (Constantan and Nichrome) and the design was optimized for thermal interface while maintaining mechanical durability. Critical design parameters including contact area between the joint and pipe, interface material selection, and hot surface geometry were systematically evaluated using the test model mimicking residential water piping and using residential hot water heater exhaust. Prototyping included 3-D designed profiles for low temperature application like residential hot water application. For higher temperature application like a residential hot water heater exhaust, a 3-D printed mold was created to create a silicone profile. Experimental results demonstrate that as a temperature difference increased, it increased power output. A performance comparison was done with a commercial TEG. At a given temperature difference, the experimental prototype design produced at least 20% more voltage per sq inch area. By integrating mechanical flexibility and thermal management into a unified engineering framework, this work establishes a scalable design pathway for distributed waste heat recovery systems capable of powering low-energy electronics and autonomous sensors without combustion, moving parts, or any kinds of emissions. By converting unavoidable heat loss into usable electrical output without adding emissions or operational complexity, our innovation contributes to the net-zero goals in a practical way.

Competition history

• CSEF 2026 Applied Mechanics (Senior Division) · Entry S-02-07

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