Designing a Hybrid Energy-Efficient Harvesting System for Head- or Wrist-Worn Healthcare Wearable Devices

Battery power is crucial for wearable devices as it ensures continuous operation, which is critical for real-time health monitoring and emergency alerts. One solution for long-lasting monitoring is energy harvesting systems. Ensuring a consistent energy supply from variable sources for reliable device performance is a major challenge. Additionally, integrating energy harvesting components without compromising the wearability, comfort, and esthetic design of healthcare devices presents a significant bottleneck. Here, we show that with a meticulous design using small and highly efficient photovoltaic (PV) panels, compact thermoelectric (TEG) modules, and two ultra-low-power BQ25504 DC-DC boost converters, the battery life can increase from 9.31 h to over 18 h. The parallel connection of boost converters at two points of the output allows both energy sources to individually achieve maximum power point tracking (MPPT) during battery charging. We found that under specific conditions such as facing the sun for more than two hours, the device became self-powered. Our results demonstrate the long-term and stable performance of the sensor node with an efficiency of 96%. Given the high-power density of solar cells outdoors, a combination of PV and TEG energy can harvest energy quickly and sufficiently from sunlight and body heat. The small form factor of the harvesting system and the environmental conditions of particular occupations such as the oil and gas industry make it suitable for health monitoring wearables worn on the head, face, or wrist region, targeting outdoor workers.

Developing High-Performance and Low-Cost Paint Thermoelectric Materials for Low-Midtemperature Applications

Most thermoelectric (TE) materials used to convert heat energy into electrical energy are expensive and, to a certain degree, toxic. Moreover, due to the chemical complexity in the synthesis process, some of the TE materials are not reproducible. Similarly, the scarcity of TE materials hampers their scalability. To address the above issues, this study presents an inexpensive, nontoxic, scalable, and highly reproducible paint-based TE module for the conversion of heat energy to electrical energy. Transport properties with structural analysis indicate that the electrical conductivity of the paint TE material is controlled by the concentration of graphite and sodium silicate, while the Seebeck coefficient is dominated by the ratio of n- and p-type Bi-Sb-Te. The results indicate that the as-developed TE module can withstand an operating temperature of up to 160 °C. At a temperature of 57 °C, the highest power factors of the as-synthesized n- and p-type TE paints are 1.34 and 1.42 μW/(cm K2), respectively. It is also found that the TE module can have a higher output voltage when the cold side of the TE module is allowed to float in the air in comparison to that when it is in contact with the human body. The performance of the paint-based TE module is measured on five parts of the body, namely, the chest, palm, leg, wrist, and neck; the wrist has the highest open-circuit voltage of 1.9 mV, indicating its suitability for wearable applications. Finally, at a temperature gradient of 30 °C, a maximum output power of 6.8 μW is attained.

Optimizing Waste Heat Conversion: Integrating Phase-Change Material Heatsinks and Wind Speed Dynamics to Enhance Flexible Thermoelectric Generator Efficiency

Flexible thermoelectric generators (FTEGs) have garnered significant attention for their potential in harnessing waste heat energy from various sources. To optimize their efficiency, FTEGs require efficient and adaptable heatsinks. In this study, we propose a cost-effective solution by integrating phase-change materials into FTEG heatsinks. We developed and tested three flexible phase-change material thicknesses (4 mm, 7 mm, and 10 mm), focusing on preventing leaks during operation. Additionally, we investigated the impact of wind speed on the output performance of FTEGs with a flexible phase-change material heatsink. The results indicate that the appropriate flexible phase-change material thickness, when integrated with considerations for wind speed, demonstrates remarkable heat-absorbing capabilities at phase-change temperatures. This integration enables substantial temperature differentials across the FTEG modules. Specifically, the FTEG equipped with a 10 mm thick flexible phase-change material heatsink achieved a power density more than four times higher when the wind speed was at 1 m/s compared to no wind speed. This outcome suggests that integrating phase-change material heatsinks with relatively low wind speeds can significantly enhance flexible thermoelectric generator efficiency. Finally, we present a practical application wherein the FTEG, integrated with the flexible phase-change material heatsink, efficiently converts waste heat from a circular hot pipe into electricity, serving as a viable power source for smartphone devices. This work opens exciting possibilities for the future integration of flexible thermoelectric modules with flexible phase-change material heatsinks, offering a promising avenue for converting thermal waste heat into usable electricity.

Evolution of Thermoelectric Generators: From Application to Hybridization

Considerable thermal energy is emitted into the environment from human activities and equipment operation in the course of daily production. Accordingly, the use of thermoelectric generators (TEGs) can attract wide interest, and it shows high potential in reducing energy waste and increasing energy recovery rates. Notably, TEGs have aroused rising attention and been significantly boosted over the past few years, as the energy crisis has worsened. The reason for their progress is that thermoelectric generators can be easily attached to the surface of a heat source, converting heat energy directly into electricity in a stable and continuous manner. In this review, applications in wearable devices, and everyday life are reviewed according to the type of structure of TEGs. Meanwhile, the latest progress of TEGs' hybridization with triboelectric nanogenerator (TENG), piezoelectric nanogenerator (PENG), and photovoltaic effect is introduced. Moreover, prospects and suggestions for subsequent research work are proposed. This review suggests that hybridization of energy harvesting, and flexible high-temperature thermoelectric generators are the future trends.

Human body heat-driven thermoelectric generators as a sustainable power supply for wearable electronic devices: Recent advances, challenges, and future perspectives

Thermoelectric generators are devices that directly convert heat flux or the temperature difference between two hot and cold surfaces into electricity. With the advancement of the Internet of Things (IoT) technology and the development of wearable and portable devices, the issue of providing a sustainable power source is one of the main challenges in the development path of these tools. Creating electric power by harvesting the waste heat from the human body is one of the effective solutions in this way. For this reason, the development and improvement of the technology of wearable thermoelectric generators have received much attention recently. Due to the low-temperature difference between the two sides of wearable thermoelectric generators and the high thermal resistance between the skin and the heated surface of these modules, the performance of these systems is highly dependent on their structural parameters and environmental factors. In this paper, it has tried to review all the previous studies regarding the impact of structural factors (such as the matching of internal and external thermal resistances, geometrical parameters of the module, design of heat source and sink, and flexibility of thermoelectric module) and environmental parameters (including the effect of ambient air temperature and humidity, skin temperature, and the interaction of power consumers with thermoelectric modules). Based on the studies, it seems that in optimizing the performance of wearable thermoelectric generators (WTEGs), it is necessary to consider the effect of the human body's thermoregulatory responses, such as skin temperature and sweating rate. The change in skin temperature directly affects the performance of WTEGs, and the change in sweating rate can also affect the thermal resistance between the skin and the hot plate and overshadow the matching of thermal resistances during operation.

High-Power-Density Wearable Thermoelectric Generators for Human Body Heat Harvesting

Wearable thermoelectrics has attracted significant interest in recent years. Among them, rigid-structure thermoelectric generators (TEGs) were seldomly employed for wearable applications, although those exhibit significant advantages of high device output performance and impact resistance. Here, we report a type of rigid wearable TEGs (w-TEGs) without ceramic substrates made using a simple cutting-and-bonding method. Owing to the small contact area, the w-TEGs comprising 48-n/p-pairs can be well attached to the human body. The lack of ceramic substrates leaves more space in the height direction, which benefits the wearability in practical applications and high power density. We demonstrated that increasing the height of w-TEGs from 1.38 to 3.14 mm significantly improves the power density by a factor of 10. As a result, the maximum power densities of 7.9 μW cm^-2 and 43.6 μW cm^-2 for the w-TEGs were realized under the breezeless condition and a wind speed for normal walking, respectively. This work provides a feasible design solution for rigid-structure free-substrate w-TEGs with very high power density, which will speed up the research of wearable thermoelectrics.

Review on Wearable Thermoelectric Generators: From Devices to Applications

Wearable thermoelectric generators (WTEGs) can incessantly convert body heat into electricity to power electronics. However, the low efficiency of thermoelectric materials, tiny terminal temperature difference, rigidity, and neglecting optimization of lateral heat transfer preclude WTEGs from broad utilization. In this review, we aim to comprehensively summarize the state-of-the-art strategies for the realization of flexibility and high normalized power density in thermoelectric generators by establishing the links among materials, TE performance, and advanced design of WTEGs (structure, heatsinks, thermal regulation, thermal analysis, etc.) based on inorganic bulk TE materials. Each section starts with a concise summary of its fundamentals and carefully selected examples. In the end, we point out the controversies, challenges, and outlooks toward the future development of wearable thermoelectric devices and potential applications. Overall, this review will serve to help materials scientists, electronic engineers, particularly students and young researchers, in selecting suitable thermoelectric devices and potential applications.

Simultaneous Realization of Flexibility and Ultrahigh Normalized Power Density in a Heatsink-Free Thermoelectric Generator via Fine Thermal Regulation

Wearable thermoelectric generators (w-TEGs) can incessantly convert body heat into electricity to power electronics. However, the low efficiency of thermoelectric materials, tiny terminal temperature difference, rigidity, and negligence of lateral heat transfer preclude broad utilization of w-TEGs. In this work, we employ finite element simulation to find the key factors for simultaneous realization of flexibility and ultrahigh normalized power density. Using melamine foam with an ultralow thermal conductivity (0.03 W/m K) as the encapsulation material, a novel lightweight π-type w-TEG with no heatsink and excellent stretchability, comfortability, processability, and cost efficiency has been fabricated. At an ambient temperature of 24 °C, the maximum power density of the w-TEG reached 7 μW/cm² (sitting) and 29 μW/cm² (walking). Under suitable heat exchange conditions (heatsink with 1 m/s air velocity), 32 pairs of w-TEGs can generate 66 mV voltage and 60 μW/cm² power density. The output performance of our TEG is remarkably superior to that of previously reported w-TEGs. Besides, the practicality of our w-TEG was showcased by successfully driving a quartz watch at room temperature.

Whole Fabric-Assisted Thermoelectric Devices for Wearable Electronics

Flexible thermoelectric generators (f-TEGs) have demonstrated great potential in wearable self-powered health monitoring devices. However, the existing wearable f-TEGs are neither flexible enough to bend and stretch while maintaining the device's integrity with a good TE performance nor directly compatible with clothes materials. Here, ultraflexible fabric-based thermoelectric generators (uf-TEGs) are proposed with conductive cloth electrodes and elastic fabric substrate. The patterned elastic fabric substrate fits the rigid cuboids well, together with serpentine structured cloth electrodes, rendering uf-TEG with excellent integrity and flexibility, thereby achieving a highly functional TE performance when strain reaches 30% or on arbitrarily shaped heat sources. The uf-TEGs show a large peak power of 64.10 μW for a temperature difference of 33.24 K with a high voltage output of 111.49 mV, which is superior compared to previously reported fabric-based TEG devices, and it is still functional after the water immersion test. Besides the energy harvesting function, with both the temperature sensing ability and the touch perception, this uf-TEG is demonstrated as the electrical skin when mounted on a robot. Moreover, due to the wind-sensitive performance and self-power ability, the uf-TEGs are assembled on cloth as wearable health and motion monitoring devices.

Experimental and Theoretical Investigation of the Effect of Filler Material on the Performance of Flexible and Rigid Thermoelectric Generators

Thermoelectric generators have found many applications where the heat source can be either flat or curved. For a curved heat source, flexible thermoelectric generators are generally used. A filler material with low thermal conductivity can provide additional mechanical support to the thermoelectric module and can reduce convection and radiation losses. Herein, the effect of three different filler materials on the output performance of rigid and flexible thermoelectric generators is investigated. At first, theoretical models are derived and the experimental study validated the models. The experimental study revealed that the flexible thermoelectric modules outperformed the rigid modules; this is due to the reduction of the number of thermal junctions in the flexible modules and due to the differences in the thermal conductivities of the flexible and rigid substrates. Likewise, among TE modules without filler/with air between the TE legs, with polyurethane foam filler material, and with polydimethylsiloxane filler material, air has the lowest thermal conductivity, and therefore, the thermoelectric generator without filler generates higher output power and higher power density than when the other two filler materials are used. For the fixed temperature gradient, the highest power densities for the flexible and rigid thermoelectric generators without filler are 155 and 137.7 μW/cm² for temperature gradients of 10.8 and 10.3 °C, respectively.

Providing Energy Self-Sufficiency to LoRaWAN Nodes by Means of Thermoelectric Generators (TEGs)-Based Energy Harvesting

The aim of this paper is to present the viability of an energy-harvesting system prototype, based on thermoelectric generators (TEGs), to be embedded in a Long-Range Wide Area Network (LoRaWAN)-based wireless sensor node, allowing continuous quasi-real-time data transmission even for low temperature gradients and for frequent transmissions. To this end, an RFM95x LoRa module is used in the system. The energy management of the entire node is achieved by exploiting a nano power boost charger buck converter integrated circuit, which allows power extraction from the energy-harvesting source and, at the same time, regulates the charging/discharging process of a Li-Po battery that supplies the wireless node. The first phase of the project was dedicated to understanding the electrical characteristics of the TEG. A series of tests were performed to study the open circuit voltage, the current and the power generated by the TEG at different temperature gradients. Following this first phase, tests were then set up to study the charging/discharging process of the battery by changing two crucial parameters: the temperature between the faces of the TEG and the frequency of the transmissions performed by the transceiver. Experimental results show a positive balance for the battery charging at different conditions, which suggests two important conclusions: first of all, with high temperature gradients, it is possible to set relatively high transmission frequencies for the LoRaWAN module without discharging the battery. The second important consideration concerns the operation of the system at extremely low temperature gradients, with a minimum of 5 °C reached during one of the measurements. This suggests the usability of thermoelectric energy-harvesting systems in a wide range of possible applications even in conditions of low temperature gradients.

Flexible Hybrid Photo-Thermoelectric Generator Based on Single Thermoelectric Effect for Simultaneously Harvesting Thermal and Radiation Energies

Wearable electronic devices have great potential in the fields of the Internet of Things (IoT), sports and entertainment, and healthcare, and they are essential in advancing the development of next-generation electronic information technology. However, conventional lithium batteries, which are currently the main power supply of wearable electronic devices, have some critical issues, such as frequent charging, environmental pollution, and no surface adaptability, which limit the further development of wearable electronic devices. To address these challenges, we present a flexible hybrid photothermoelectric generator (PTEG) with a simple structure composed of a thermoelectric generator (TEG) and a light-to-thermal conversion layer to simultaneously harvest thermal and radiation energies based on a single working mechanism. The mature mass-fabrication technology of screen printing was applied to successively prepare n-type (i.e., Bi₂Te_2.7Se_0.3) and p-type (i.e., Sb₂Te₃) thermoelectric inks atop a polyimide substrate to form the TEG with a serpentine thermocouple chain, which was further covered by a light-to-thermal conversion layer to constitute the PTEG. The resulting PTEG with five pairs of thermocouples generated a direct-current output of 82.4 mV at a temperature difference of 50 °C and a direct-current output of 41.2 mV under 20 mW/cm² infrared radiation. Meanwhile, the remarkable mechanical reliability and output stability were experimentally demonstrated through a systematic test, which indicated the feasibility and potential of the developed PTEG as a reliable power source. In addition, as desirable application prototypes, the fabricated PTEGs have been successfully demonstrated to harvest biothermal energy and infrared radiation to drive portable electronic devices (e.g., a calculator and a clock). Hybrid energy harvesting technology based on a simple structure may provide a new solution to current power supply issues of wearable electronic device.

An Origami Heat Radiation Fin for Use in a Stretchable Thermoelectric Generator

Recently, some studies have addressed the use of a folded substrate to realize stretchable electronic devices including stretchable thermoelectric generators (TEGs). However, the utilization of the folded substrate as a heat radiation fin has not been achieved. Herein, we have proposed the construction of a TEG with an origami-like folded structure substrate called an “origami-fin” that can achieve a high heat radiation performance and is also highly stretchable. The origami-fin increases the stretchability of the TEG by bending a non-stretchable material into a folded shape, and it also works as a heat radiator because of its large surface area compared to that of a flat structure. We evaluated the heat radiation performance of the origami-fin and the stability of the performance when it was stretched. The results demonstrate that the origami-fin works as a heat radiator and enhances the output of the TEG, while also exhibiting a high stretchability with only a slight output reduction.

Plant Microbial Fuel Cells⁻Based Energy Harvester System for Self-powered IoT Applications

The emergence of modern technologies, such as Wireless Sensor Networks (WSNs), the Internet-of-Things (IoT), and Machine-to-Machine (M2M) communications, involves the use of batteries, which pose a serious environmental risk, with billions of batteries disposed of every year. However, the combination of sensors and wireless communication devices is extremely power-hungry. Energy Harvesting (EH) is fundamental in enabling the use of low-power electronic devices that derive their energy from external sources, such as Microbial Fuel Cells (MFC), solar power, thermal and kinetic energy, among others. Plant Microbial Fuel Cell (PMFC) is a prominent clean energy source and a step towards the development of self-powered systems in indoor and outdoor environments. One of the main challenges with PMFCs is the dynamic power supply, dynamic charging rates and low-energy supply. In this paper, a PMFC-based energy harvester system is proposed for the implementation of autonomous self-powered sensor nodes with IoT and cloud-based service communication protocols. The PMFC design is specifically adapted with the proposed EH circuit for the implementation of IoT-WSN based applications. The PMFC-EH system has a maximum power point at 0.71 V, a current density of 5 mA cm - 2 , and a power density of 3.5 mW cm - 2 with a single plant. Considering a sensor node with a current consumption of 0.35 mA, the PMFC-EH green energy system allows a power autonomy for real-time data processing of IoT-based low-power WSN systems.

Coaxial struts and microfractured structures of compressible thermoelectric foams for self-powered pressure sensors

Long-term operation of wearable pressure sensors to detect body movement requires self-powered human-based energy sources to minimize the need for recharging. Recently, pressure sensors with thermoelectric properties based on conducting polymers have been reported; however, these devices are limited in their ability to simultaneously achieve sufficient power generation and sensitivity of the sensor. In this article, we suggest a coaxial strut structure of poly(styrene-ethylene/butylene-styrene)(SEBS)-poly(3,4-ethylenedioxythiophene):poly(styrenesulfonate)(PEDOT:PSS)-melamine foam (MF) with a fractured microstructure for a highly sensitive, efficient self-powered pressure sensor. In the coaxial struts, the MF core provides a compressible and elastic framework; the intermediate PEDOT:PSS acts as a conductor and a thermoelectric material; and the SEBS shell ensures mechanical stability and resilience to stabilize the brittle PEDOT:PSS layer under high loading conditions. Additionally, by compressing the coaxial foam to 1/20, partial microfracture of PEDOT:PSS occurs only in the SEBS shell; thus, the pressure sensitivity increases significantly while maintaining high conductivity and thermoelectric performance. The coaxial foam was assembled into a wearable TEG to generate 338 nW from the forearms and demonstrate the high sensitivity of pressure sensors without an external power supply.

Development of a Thermoelectric and Electromagnetic Hybrid Energy Harvester from Water Flow in an Irrigation System

A hybrid energy harvester is presented in this paper to harvest energy from water flow motion and temperature difference in an irrigating pipe at the same time. The harvester is based on the integration of thermoelectric and electromagnetic mechanisms. To harvest the water flow motion, a turbine fan with magnets that are attached on the blades is placed inside of the water pipe. Multiple coils turn the water flow energy into electricity with the rotation of the turbine. The thermoelectric generators (TEGs) are attached around the pipe, so as to harvest energy due to temperature difference. For a maximum temperature difference of 55 °C (hot side 80 °C and room temperature 25 °C), twelve serial-connected TEGs can generate voltage up to 0.346 V. Under a load resistance of 20 Ώ, the power output of 1.264 mW can be achieved. For a maximum water flow rate of 49.9 L/min, the electromagnetic generator (EMG) can produce an open circuit voltage of 0.911 V. The EMG can be potentially used as a water flow meter due to the linear relationship between water flow rate and output voltage. Under the joint action of TEG and EMG, the maximum terminal voltage for TEG is 66 mV and for EMG is 241 mV at load resistances of 10 and 100 Ώ, respectively, resulting in a corresponding power output of 0.435 and 0.584 mW.

Design of Substrate Stretchability Using Origami-Like Folding Deformation for Flexible Thermoelectric Generator

A stretchable thermoelectric (TE) generator was developed by using rigid BiTe-based TE elements and a non-stretchable substrate with origami-like folding deformation. Our stretchable TE generator contains flat sections, on which the rigid TE elements are arranged, and folded sections, which produce and guarantee the stretchability of a device. First, a simple stretchable device with a single pair of p-type and n-type BiTe-based TE elements was designed and fabricated. The TE elements were sandwiched between two folded polyimide-copper substrates. The length of the wiring between the flat sections changed from 1.0 mm in the folded state to 1.8 mm in the deployed state. It was also confirmed that the single-pair device could generate power in both the folded and deployed states. After this, a stretchable TE generator with eight pairs of p-type and n-type BiTe-based TE elements connected in series was created. The stretchable TE generator was capable of withstanding a stretching deformation of 20% and could also produce an output voltage in both the folded and deployed states.

Zinc Oxide-Enhanced Piezoelectret Polypropylene Microfiber for Mechanical Energy Harvesting

This paper reports zinc oxide (ZnO)-coated piezoelectret polypropylene (PP) microfibers with a structure of two opposite arc-shaped braces for enhanced mechanical energy harvesting. The ZnO film was coated onto PP microfibers via magnetron sputtering to form a ZnO/PP compound structure. Triboelectric Nanogenerator (TENG) based on ZnO/PP microfiber compound film was carefully designed with two opposite arc-shaped braces. The results of this study demonstrated that the mechanical energy collection efficiency of TENG based on piezoelectret PP microfiber was greatly enhanced by the coated ZnO and high-voltage corona charging method. We found that, with the step-increased distance of traveling for the movable carbon black electrode, an electrical power with an approximately quadratic function of distance was generated by this mechanical-electrical energy conversion, because more PP microfibers were connected to the electrode. Further, with a full contact condition, the peak of the generated voltage, current, and charges based on the ZnO/PP microfibers by this mechanical-electrical energy conversion with 1 m/s² reached 120 V, 3 μA, and 49 nC, respectively. Moreover, a finger-tapping test was used to demonstrate that the ZnO/PP microfiber TENG is capable of lighting eight light-emitting diodes.