WO2015112591A1

WO2015112591A1 - Packable electric generator

Info

Publication number: WO2015112591A1
Application number: PCT/US2015/012235
Authority: WO
Inventors: Jonathan N. CEDAR; Alexander H. Drummond; Nisan H. LEREA; Anton Olof LJUNGGREN; Whitney GOODWIN; Monte MACDIARMID; Tracy Van Dyk
Original assignee: Biolite Llc
Priority date: 2014-01-21
Filing date: 2015-01-21
Publication date: 2015-07-30

Abstract

The packable electric generator can be used on a variety of heat sources. The power-generating kettle device includes a TEG that produces electrical power during the boiling process. The kettle device is provided with a handle assembly comprising a top handle cover, a handle base, a Universal Serial Bus port, a spring loaded on/off switch, a light-emitting diode display, a power storage battery and a controller contained within the handle assembly; a body housing assembly that is a vessel for containing a removable volume of liquid and for retaining the volume during heating, further comprising a top and co-formed outer perimeter wall having a hole and a hinge assembly; a base sub-assembly comprised of a puck, an O- ring, a wire channel and a sheet metal vessel bottom; and a TEG clamping sub-assembly comprising a thermal electric generator for generating electric power and a heat exchanger plate.

Description

PACKABLE ELECTRIC GENERATOR

FIELD OF THE INVENTION

[0001] The present invention relates generally to thermal electric generator kettle devices, and more particularly to a power-generating kettle.

BACKGROUND OF THE INVENTION

[0002] The Thermal Electric Generator (TEG) is a useful device that converts temperature differentials into electric energy. Placing a TEG in a kettle device near a heat source will result in electrical generation. The TEG has a limit for heating on the hot side that, if unchecked, can result in damage to the TEG and a loss of its usefulness. Controlling the temperature of the TEG by providing a heat sink medium can prevent damage to the TEG. The TEG can utilize a medium to carry off excess heat during use. Air is one such medium, but requires a circulation system. Another cooling medium is a liquid, for example, water. One advantage to using water is that the application of heat changes its state from a liquid to a gas, and the resulting steam flows out any given opening, removing the excess heat without a need for a secondary circulation system or pumps. Water has the advantage of being a non-toxic medium and abundant.

[0003] The heat source for heating a TEG can be a combustion device. Another can be a conventional stove top. There exist a variety of portable combustion devices that may be used, for example, as a stove for cooking or heating, among other uses. In the past, portable combustion devices required a variety of fuels such as those used for liquid fuel stoves, portable and fixed wood stoves and compressed gas fuel stoves. These stoves were used in a variety of different situations such as for camping, emergency or rescue situations, in the event of a power outage a gas cook range or gas BBQ grill could provide the heat source for generation of electricity.

[0004] Accordingly, it is desirable to provide a TEG device that can utilize most any heat source and use a convenient heat sink medium, such as water. It is further desirable to provide a device that includes both a TEG for the active generation of energy during use and a battery storage device that can store additional power when the TEG is not in operation. The TEG device can desirably employ inexpensive and commercially available components and conventional construction techniques in its manufacture. SUMMARY OF THE INVENTION

[0005] The present invention overcomes the disadvantages of the prior art by providing a refillable packable electric generator that can be used on a variety of heat sources. The power-generating kettle device includes a TEG that produces electrical power during the boiling process. The kettle device is provided with a handle assembly comprising a top handle cover, a handle base, a Universal Serial Bus port, a spring loaded on/off switch, a light-emitting diode display, a power storage battery and a controller contained within the handle assembly; a body housing assembly that is a vessel for containing a removable volume of liquid and for retaining the volume during heating, further comprising a top and co-formed outer perimeter wall having a hole and a hinge assembly; a base sub-assembly comprised of a puck, an O-ring, a wire channel and a sheet metal vessel bottom; and a TEG clamping subassembly comprising a thermal electric generator for generating electric power and a heat exchanger plate.

[0006] In practice, the user raises the handle and adds water to fill the vessel. The kettle device is then placed in proximity to, e.g., atop of, a heat source. Within minutes the heat passing through the bottom of the kettle passes into the water, causing to boil, and activates the TEG, which generates electricity. The generated electricity is supplied to the handle assembly. The status display can indicate preset levels for temperature and battery charge. The generated electricity can be transferred directly or indirectly to an electronic device via a cable at an engaged receptacle plugged into a port and/or stored in the storage battery.

[0007] A packable electric generator comprising a hinged handle assembly comprising a top handle cover, a handle base, a port, a spring loaded on/off switch, a light- emitting diode display, a power storage battery, a wire array and a controller contained within the handle assembly; a body housing assembly that is a vessel for containing a removable volume of liquid and for retaining the volume during heating, further comprising a top and co-formed outer perimeter wall having a hole and a hinge assembly; a base sub-assembly comprised of a puck, an O-ring, a wire channel and a sheet metal vessel bottom; and a TEG clamping sub-assembly comprising a thermal electric generator for generating electric power and a heat exchanger plate. The packable electric generator is an enclosed vessel for the heating of a volume of water that is a heat sink for a TEG that resides within the bottom of the vessel. The vessel generates electricity as the vessel is heated and water can be inserted into, and removed from, the vessel. The handle is provided with a power storage battery that is accessible for the withdrawal of stored power when the TEG is or is not generating power. The handle is constructed and arranged to have a USB port that is accessible for the withdrawal of electric power whether the TEG is generating electricity or the TEG is inactive. The controller manages the power output and distribution. The hot side of the TEG is in proximity to the heat exchanger plate and the cold side is in proximity to the puck and the puck is an elevated cold side heat exchanger for the TEG. The user interface determines when a level of the liquid contained in the vessel is low and gives a warning alert prior to overheating of the TEG. The device is constructed and arranged wherein the wiring array is internal so as to be concealed from view and protected from thermal energy. A method of charging an electronic device, comprising the positioning of the packable electric generator in proximity to a heat source, the packable electric generator having a volume for receiving a liquid configured to be heated by the heat source; generating an electric current using the packable electric generator based in part on heat from the heat source; charging a battery with the electric current; powering the electronic device with the battery; sensing an output voltage of the battery while powering the electronic device; and controlling the electric current generated by the packable electric generator based in part on the output voltage of the battery. Controlling the electric current comprises activating a short circuit in the packable electric generator when the output voltage is above a first threshold. Controlling the electric current further comprises deactivating a short circuit in the packable electric generator when the output voltage is below a second threshold. A packable electric generator, comprising a body assembly comprising a thermal electric generator (TEG) and defining a volume configured to receive a liquid, the TEG being configured to generate an electric current based in part on a temperature of the liquid and a handle assembly operatively connected to the body assembly, the handle assembly comprising a rechargeable battery and a port configured to charge an electronic device.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The invention description below refers to the accompanying drawings, of which: [0009] Fig. 1 is a perspective view of a packable electric generator according to the illustrative embodiment;

[0010] Fig. 2 is an exploded perspective view of the packable electric generator showing the component sub-assemblies according to the illustrative embodiment;

[0011] Fig. 3 is an exploded perspective view of the handle assembly according to the illustrative embodiment;

[0012] Fig. 4 is an exploded view of the body sub-assembly, base sub-assembly and

TEG clamping sub-assembly according to the illustrative embodiment;

[0013] Fig. 5 is a side view of the packable electric generator with a raised and locked handle according to the illustrative embodiment;

[0014] Fig. 6 is a side view of the packable electric generator with a folded handle according to the illustrative embodiment;

[0015] Fig. 7 is a view of an interface for the packable electric generator according to the illustrative embodiment;

[0016] Fig. 8 is a perspective view of an exemplary packable generator being heated on top of an illustrative propane range top surface according to the illustrative embodiment;

[0017] Fig. 9 is perspective of the body housing according to the illustrative embodiment;

[0018] Fig. 10 is a cross section of the body housing along lines 10-10 of Fig. 1 according to the illustrative embodiment;

[0019] Fig. 1 OA is a detailed cross section of a portion of the view of Fig. 10 according to the illustrative embodiment;

[0020] Fig. 1 1 is the cross section of the body housing of Fig. 10 during the heating process according to the illustrative embodiment;

[0021] Fig. 12 is a schematic block diagram of the electrical components of the exemplary packable electric generator according to the illustrative embodiment;

[0022] Fig. 13 is an illustrative packable electric generator having a flat top surface according to a first alternate embodiment;

[0023] Fig. 14 is an illustrative packable electric generator having a square profile body housing according to a second alternate embodiment; and [0024] Fig. 15 is a cross-section of a TEG connection with the bottom plate according to a third alternate embodiment.

DETAILED DESCRIPTION

I. General

[0025] The present disclosure provides a packable electric generator that is a power- generating kettle for use on a variety of heating sources. Figs. 1-4 show the kettle device in assembled and disassembled states. Fig. 1 depicts an exemplary kettle device 100 that is a packable electric generator. The kettle device is provided with a handle assembly 1 10. The handle can be raised into a locked raised position, as depicted in Fig. 1, or lowered into a storage position, as will be explained more fully later. The packable electric generator has two operational stages, a heating/power generation stage, during which the kettle device is in proximity to and subjected to heating and power is generated by the TEG, and a cold storage stage, during which the kettle device is not heated and residual electric power is stored in an on-board battery. The handle assembly contains a controller, a battery and various other electrical components that are part of the control of the kettle device, which will be described in greater detail below. The exterior upper surface of the handle assembly is provided with an interface 112, an on/off switch 114, a port 1 16, e.g., Universal Serial Bus ("USB"), and a spring-loaded latch 1 18.

[0026] The hinged handle assembly 110 becomes a handle when raised and locked that facilitates handling the kettle device, for example, positioning it on a heat source or dispensing heated water. The raised handle removes the battery, controller and other electrical components from close proximity to the top surface 120 of the kettle device when in use, thereby preventing damage to those components during the heating and power generation stage of operation. When the handle assembly 110 is raised to the locked raised position, that raising is halted by the latch mechanism 1 18 engaging locking slots (not shown) in the hinge assembly 122. All of the wiring from the TEG to the handle electrical components and within the handle comprises a wiring array that is internal so as to be concealed from view and protected from thermal energy.

[0027] Fig. 2 depicts the major sub-assemblies of the kettle device 100. The vessel of the packable electric generator is within a body housing assembly 130. The vessel is described as the interior volume of the kettle device that is constructed and arranged to contain a refillable volume of water. The liquid capacity is up to 750 mL. The body housing assembly 130 is comprised of a body sub-assembly 140, a base sub-assembly 150 and a TEG clamping sub-assembly 160. The various parts of these sub-assemblies will be described more fully below.

[0028] The components of the handle assembly 110 are depicted in Fig. 3. The body of the handle is formed by the connection of the top handle cover 302 and the handle base 304. The material of the top handle cover 302 and the handle base 304 is a polymer, for example nylon and it is formed by an injection molding process. In other embodiments, it is contemplated that another polymer can be used for the handle material. The top handle cover 302 is provided with a port well 306 and an interface well 308. With regards to the port well 306, there are three through-holes for the spring-loaded latch, USB port and a locking screw. The port provides for the transfer of electrical power from the kettle device to another electronic device during both the power generation stage and storage stage. The latch through-hole 310 is sized to receive the latch 312 and to provide room for movement of the latch 312. The through-hole 314 is sized to permit the passage of a USB connector (not shown) into the through-hole so that it can enter the USB opening 316 and removably engage the USB port 318. The USB port 318 is secured by at least one USB locking screw 319. While a USB port is described above, other types of ports can be used. A locking screw through-hole 320 is provided for the insertion of a locking screw 322 that will removably engage a mount 324 located on the interior surface of the handle base 304. The USB port is covered by a USB cover 323 that is made of an elastomeric polymer, for example, rubber or silicone. While a USB port is shown in FIG. 3, the port can be any type of port capable of charging an electronic device, such as micro-USB, mini-USB, Firewire, or a two/three prong electrical outlet.

[0029] Interface well 308 houses the visual displays for the status of the kettle device and an on/off switch. The interface well 308 is covered by a translucent cover 326. Two locking screws 322 pass through through-holes 328 into mounts 324 that are located on the interior surface of the handle base 304 and unite the top handle cover 302 with the handle base 304. The on-off switch 332 actuates the kettle device electronics when the kettle device is in the cold stage and review of the status of the battery storage capacity and activates the USB port for charging external devices. The kettle device automatically powers up the onboard electronic components when heat is introduced. A LED (light-emitting diode) array 332 is positioned on the interior surface of the handle base 304 and is in electrical contact with the controller 333 (not shown) located within the handle base. The LED array 332 includes a plurality of LED elements 334 that are visible when actuated through a plurality of windows 336. The LEDs are positioned so as to be in contact with electrical contact points 338 that are connected to the controller. The LED array is depicted as having nine LED elements. In other embodiments, the LED array can have more or less LED elements.

[0030] A storage battery 340 resides within a battery well 342 that is constructed and arranged within the handle base 304. The battery 340 is in electrical contact with the controller 333. The battery storage has a capacity of 3 watt hours. The battery is a rechargeable lithium battery and can be a lithium iron disulfide (Li-FeS₂) type battery. In other embodiments, a different type of battery of another capacity can be used and charge capacities can vary accordingly. A pair of hinge covers 350 engages the hinge assembly 122 and is secured to the handle base 304 by four locking screws 352. The handle base has a recessed lip 354 and a curved section 356 along the bottom surface 358 to conform with the geometry of the top surface of the body housing, as will be described more fully below.

[0031] Fig. 4 shows the body 130 sub-assemblies. The body sub-assembly 140 is comprised of the hinge assembly 122, the body housing 400 and three rivets 402 for securing the hinge assembly 122 to the body housing 400. The body sub-assembly 140 includes a perimeter wall co-formed with the top. The top surface 120 is comprised of a raised shoulder 404 and a well 406. The hinge assembly 122 is seated within a detented portion 408 of the shoulder 404. A channel hole 410 is provided in the detented portion 408 to allow an electrical cable to pass from the TEG to the handle assembly electrical components, as will be more fully described below. The exterior wall surface 412 is sloped inwards from the bottom to the top such that the top perimeter is narrower and smaller than the bottom perimeter. The shoulder 404 is perforated by a water opening 414, one wall of which is formed into a pouring spout 416. The spout 416 is positioned so as to be opposite and counterpoised to the detented portion 408 and provides for the lip 354 of the closed handle assembly 110 to cover the water opening. This is a non-sealing covering. In other embodiments, the lip 354 can be provided with an elastomeric gasket and form a seal with the water opening. The water opening 414 and spout 416 are constructed and arranged to allow water to be inserted into the interior vessel portion of the packable electric generator and for the dispersal of heated water, for example, to make a cup of tea. The body housing 400 is constructed of stamped stainless steel sheet metal. In other embodiments, other sheet metal products can be used to form this housing.

[0032] The base sub-assembly 150 is comprised of a puck 420, an O-ring 422, a channel 424 and a sheet metal vessel bottom 426. The base sub-assembly 150 functions as part of a heat exchanger mechanism during the heating/electrical generation stage of operations. This heat exchanger functions by drawing heat through the bottom of the kettle device and discharging that thermal energy into the TEG and the liquid in the vessel. The puck 420 is a forged aluminum disk that transfers thermal energy from the "cold" side of the TEG (more fully described below) and into the surrounding water contained in the vessel. The TEG is in proximity to the heat exchanger plate on the hot side of the TEG, and to the puck 420 on the cold side of the TEG. In this regard, the water serves as a heat sink. The puck 420 is connected to the vessel bottom 426 and covers a central aperture 428 that is surrounded by a raised shoulder 430. A plurality of raised concentric ribs 431 surround the raised shoulder 430 and provides reinforced rigidity to the structure. The puck is seated on an O-ring 422 and is secured by six locking bolts 432. The O-ring is made of silicone or another similar material considered safe for use with food products. The vessel bottom 426 is made of stamped stainless steel. In other embodiments, other sheet metals can be used for form this plate. The vessel bottom 426 is provided with a wire channel conduit 432 that is raised from the vessel bottom 426. This provides a channel for electrical wires that run from the TEG to the handle. An aperture 434 aligns with the channel 424 and a wire cable can pass between the TEG clamping sub-assembly 160 and the bottom surface of the vessel bottom 426 from the TEG, through the aperture 434 and into the cylindrical channel, up through the channel hole 410 and into the handle assembly. This passage protects the wire from direct exposure to the heat source, as well as visually concealing the wire. This concealment and removal from direct contact with the heat source extends the life of the wire cable and preserves the efficiency of the movement of generated electricity from the TEG to the handle electrical components. [0033] The TEG clamping sub-assembly 160 is a part of the heat exchanger mechanism and together with the base sub-assembly 150 forms the bottom of the vessel. The heat exchanger plate 450 is provided with a raised central region 452 that serves as the base for the TEG 454. The thickness CRT of the central region 452 is greater than the thickness OBT of the surrounding region 456 of the heat exchanger plate 450. The bottom surface 458 of the heat exchanger plate 450 is in direct contact with the heat source and is the hottest portion of the packable electric generator. As will be described more fully below, heat is transferred from the bottom surface by the heat exchanger plate 450 both through the raised central region 452 and into the TEG 454, and through the surrounding region 456 and into the base sub-assembly 150 above. The relative thickness of the raised central region 452 improves rigidity where needed to support the TEG and light where not needed, in the surrounding area. The bottom surface 459 of the TEG is in direct contact with the top surface 460 of the raised central region 452 and becomes the "hot" side of the TEG 454 when in the heating/power generation stage of operations. Likewise, the top surface 462 of the TEG 454 becomes the "cold" side of the TEG during the heating/power generation stage of operations. The TEG is mounted to the top surface 460 by two bolts 464 that are provided with both standard washers 465 and Belleville washers 466 and pass through two through-holes 468 to reside in the puck 420. The Belleville washers maintain a torque force upon the bolts and contributes to the security of the TEG mounting. It is contemplated that a layer of thermal resistant epoxy can be applied to the top 460 as a bead to the perimeter of the TEG 454 or as a fillet therebetween.

II. Mechanical System

[0034] Fig. 5 shows the exemplary packable electric generator 100 of Fig. 1 with the handle assembly in the locked raised position. The handle assembly 110 is raised and locked and engaged with preset angular orientation of the hinge assembly during use. This configuration facilitates manipulation of the kettle device and also removes the handle electronics (including the controller, battery, LED display and other related components) from proximity with the heated body 130 during heating and power generation. This configuration removes the lower lip 354 from its stored position in proximity to the spout 416 and the vessel can be filled with water and/or water can be poured from the vessel. As noted above, the hinge assembly 122 comes to a locked position that is maintained until the release of the latch 1 18. The raised locked configuration has a raised angle Θ of approximately 45 degrees, e.g., 45 degrees +/- 5 degrees, that is defined as the angular difference between an axis 502 that is drawn along the center of the handle assembly 1 10 and that extends longitudinally through the length of the handle assembly and a horizontal axis 504 that extends laterally along the top surface 506 of the body 130. In other embodiments, the raised angle can be greater or lesser. The handle assembly 1 10 has a first locked position, in the raised locked position, and a second locked position, where the handle assembly resides along the top surface 506 of the body. The weight of the packable electric generator when filled with water is approximately 1 kg. In other embodiments, this weight can be greater or lesser depending on the size of the kettle device and volume of the vessel. The handle assembly and lock assembly are constructed and arranged to maintain the locked

configuration when the vessel is filled with liquid. The handle assembly 1 10 has an overall length HL of approximately 180 mm and a width HTW of approximately 28 mm. The body has a width BW of approximately 61 mm. The width of the body of the kettle device varies, with an upper width BUW of approximately 180 mm along the top surface 506 of the body 130, and a bottom width BBW of approximately 190 mm along the bottom surface 508 of the body. In other embodiments, these dimensions can vary as the size and volume of the vessel are increased or decreased.

[0035] When the heating and generation stage of operation has been concluded, the latch 1 18 can be actuated and the handle is lowered to a second locked position with the handle assembly 1 10 in proximity to the top surface 506 of the body and the lower lip 354 in proximity to the spout 416, as depicted in Fig. 6. This position optimizes the kettle device for storage and reduces the overall height of the kettle device.

[0036] Fig. 7 shows the status interface 1 14 for the kettle device that is positioned on the upper surface of the handle assembly 1 10. The interface 114 is comprised of two rows 702, 704 of LEDs 336, an on/off button 1 14 and a power on LED indicator 706. Rows 702, 704 are oriented in the same direction as the handle axis 502 and are each comprised of 4 LEDs 336. In other embodiments, the arrangement of the LEDs can vary (for example, in rows that are perpendicular to axis 502) and the number of LEDs in each row can be greater or lesser than four each, regardless of the other. The LED displays are actuated by instructions from the controller (not shown). In the illustrative embodiment, a first row 702 of LEDs 336 displays in increasing order the status of the temperature of the "hot" side of the TEG. A second row 704 of LEDs 336 displays in increasing order the status of the battery charge. In other embodiments, the rows can be reversed. The status lights are initiated and will vary in display based on preset settings for temperature and batter charge. With respect to the TEG temperature row 702, the first position LED 712 represents the lowest temperature. The initiation of the heating/generation stage automatically turns the controller on and turns on the display. At this point, the water in the vessel is either unheated or beginning to heat and the "hot" side of the TEG is still relatively cool, the temperature differential between the respective sides of the TEG is low. The controller turns on LED 712.

[0037] Increasing heat causes the temperature to rise on the bottom of the kettle device and the next preset temperature is attained. The controller switches on the second LED 714. The temperature differential between the respective TEG sides is increasing, and that in turn increases the power output of the TEG. When the next preset temperature setting is reached, the controller turns on LED 716. As the temperature rises higher, the final preset temperature setting is reached and the controller turns on LED 718. If the temperature rises above this level, an alarm will sound, as will be set forth more fully below.

[0038] The battery charge row 704 shows the charge available by a sequence of LEDs

336 that range from lowest to highest. The controller reviews the charge status according to preset levels. The first LED 720 is turned on by the controller when the charge is at the lowest level. A second LED 722 is turned on by the controller at a next preset level. A third LED 724 is turned on by the controller at a next preset level. A fourth LED 726 is turned on by the controller at the next and highest preset level. When the kettle device is in the unheated stage the level of battery charge can be accessed by the on/off switch 114. Indicator light 706 is illuminated when the TEG is generating power. In an embodiment, the LEDs 336 are all uniform in color when illuminated. In other embodiments, the LEDs can be color coded (for example, red for the lowest, yellow for the next highest, and green for the highest two).

[0039] Fig. 8 shows the packable electric generator 100 of Fig. 1 with the handle assembly 110 in the raised lock configuration and positioned on top of an illustrative propane range top 800 with an activated heating propane stove element 802. The packable electric generator can be used in this manner in remote locations that do not have electrical lines and rely instead on propane or other heat sources. In practice, the user raises the handle and adds water to fill the vessel. The kettle device is then placed on a heat source. Within minutes the heat passing through the bottom of the kettle heats the TEG, which generates electricity, and is passed into the water, causing it to boil. The thermal energy from the propane stove element 802 is transferred into the bottom surface 458 of the kettle device by direct contact. In other embodiments the heat source can be a camp fire, barbecue grill, camp stove, can of burning fuel, or other heat source. The heating of the kettle device causes the TEG to generate electricity. The water in the vessel begins to interact with the cold side of the TEG and thermal energy is transferred into the water, turning some to steam, which carries energy out the spout hole 414 to escape the vessel. The generated electricity is carried into the handle assembly 1 10. The status display 1 14 is indicating preset levels for temperature 804 and battery charge 806. The generated electricity can be transferred to an electronic device via a cable 808 at an engaged receptacle 810 plugged into the port 314 and/or stored in the storage battery.

[0040] The details of the hinge assembly 122 and wire channel connection with the handle assembly are shown in greater detail in Fig. 9. The hinge is constructed and arranged with sidewalls 901. Each sidewall is provided with a first locking notch 902 and a second locking notch 904. The first locking notch 902 receives the engaging portion of the spring- loaded latch (not shown) and removably locks the handle into the raised configuration. The second locking notch 904 is engaged by the latch and removably locks the handle into the closed configuration. As set forth above, generated electricity is transferred from the TEG to the handle electronic components via a series of internal channels. The power cable passes through the hinge assembly 122 at channel hole 410 and into a flexible channel 906. The cable passes from the flexible channel 906 into an aperture 908 within the latch 312. A coil spring 910 that provides the latch with rebounding energy when compressed resides with the aperture 908 and the cable passes through the center of the spring 910 to pass into the controller (not shown).

[0041] The body sub-assembly is shown in cross-section in Fig. 10. The wire cable

1000 is depicted as connecting with the TEG 454 and passing through the wire channel conduit 432 and aperture 434. The cable 1000 passes through the vertical channel 424 and channel hole 410. The vessel 1002 is a volume that is surrounded by the top surface 1004 of the puck 420 and the top surface 1006 of the bottom plate 426, on the sides by the inner surface 1007 of the body housing 140 and the bottom surface 1008 of the top cover 1010. The body sub-assembly 130 is an enclosed and/or enlacing structure that restricts access to the water source except at a small opening 314.

[0042] Fig. 10A is a detail of the view of Fig. 10 showing the layering of the puck

420, TEG 454 and heat exchanger plate 450. The TEG 454 is locked in place between the layers of the puck 420 and heat exchanger plate 450 and in direct contact with both of those layers.

[0043] The application of heat to the kettle device is shown in Fig. 11. The vessel 1002 contains a portion of water 1100. The interior surfaces of the volume are all stainless steel, except for the aluminum puck 420. Water can be used as the heat sink medium of the volume. In other embodiments, the medium can be a broth or another liquid, but the heating quality and ranges of the medium will vary, depending on that medium, affecting the effectiveness of the TEG. The performance of the TEG is optimized for use of water as the heat sink medium in the vessel.

[0044] The cable 1000 is connected to the controller 11 10 at one end, and the TEG

454 at the other. The controller, as will be described more fully below, can distribute the electricity to at least one of the display electronics 1 120, the power storage battery 340 and the port 318. Generated steam from the medium passes out of the vessel 1002 at the opening 314 and spout 416. When the charging process is completed, the medium can be dispersed. For example, when the battery is charged, the heated water can be poured out to make instant coffee. If the water volume falls too much and the top side of the puck 420 is exposed. Elevating the puck above the bottom surface of the vessel allows for the water level to drop below the top surface of the puck 420, which slightly reduces the heat sinking ability of the puck. This results in a slight, but detectable, temperature rise of the "cold" side of the TEG, which allows for the 3-4 minutes of warning A buzzer alarm located in the controller is activated, giving a warning time of 3 to 4 minutes before the liquid medium has completely disappeared and overheating of the TEG occurs. Once the water level falls below the bottom surface 459 of the puck, then the puck loses its heat sinking ability completely and the temperature of the "cold" side of the TEG rises quickly. At this moment, the user has the choice of removing the packable electric generator from the heat source or adding more liquid to the vessel

III. Electrical System

[0045] Fig. 12 depicts a block diagram of an exemplary control system 1200 of the kettle 100 according to one or more aspects of the disclosure. As shown, the system 1200 can include a controller 1210. The controller 1210 can be any type of processor, such as an analog microprocessor or digital microprocessor, and can include one or more processors. The controller 1210 can also include a temporary or permanent memory for storing data or instructions that can be called, retrieved, performed, or executed by the controller 1210.

[0046] The system 1200 can include a TEG 1220, e.g., TEG 454 as shown above in

FIG. 4. As described above, the TEG 1220 can generate an electrical current based on a temperature differential between the "hot" and "cold" sides. The magnitude of the current can be in proportion to the difference in temperature between the two sides of the TEG 1220.

[0047] The TEG 1220 can be directly or indirectly connected to a battery 1230. The battery 1230 can be any type of battery, such as a rechargeable battery. In one example, the battery 1230 can be a lithium-ion battery, such as a lithium-iron disulfide battery. In other examples, any type of battery 1230 can be chosen based on any number of factors, such as physical size, charge/discharge efficiency, discharge rate, cycle durability, or cell voltage.

[0048] As discussed above, the TEG 1220 can provide an electrical current to the battery 1230. In turn, the battery 1230 can be charged by the electrical current provided by the TEG 1220. The battery 1230 can store the charge and thereby charge a device connected directly or indirectly to the port 1250. The device can be, for example, a computing device, such as a personal computer, laptop, tablet, mobile phone, smart phone, or wearable computing system. The device can be any other type of device that is capable of being charged and/or discharged.

[0049] The controller 1210 can monitor or measure parameters of the TEG 1220 and/or the battery 1230 and control either or both of the TEG 1220 and/or battery 1230 based in part on the monitored or measured parameters. For example, the controller 1210 can monitor a current output of the TEG 1220. If the current output is too high, e.g., greater than a current threshold, this can indicate that there is a malfunction of the TEG 1220 or that a liquid level is too low. As described above, when the liquid level is too low, this can result in mechanical damage to the TEG 1220 or the kettle 100 in general. In this regard, the controller 1210 can compare the current output to a first current threshold such that, when the current is greater than the first threshold current, a warning or alarm is displayed at the user interface 1260, or additionally or alternatively, the kettle 100 is disabled. In another example, the controller 1210 can monitor a temperature of the cold side of the TEG 1220. In this regard, if the temperature of the cold side is greater than a predetermined temperature threshold, then an alarm or warning state may be displayed at the user interface 1260 or additionally or alternatively, the kettle 100 is disabled. The first current threshold can be any threshold, and can be predetermined, stored in a lookup table, or can be determined by an algorithm.

[0050] Additionally, if the current output of the TEG 1220 is too low, e.g, is below a second threshold current, this can indicate that the TEG 1220 is no longer exposed to the temperature differential necessary to generate a current. In this regard, the controller 1210 can deactivate any of the battery 1230, boost circuit 1240, port 1250, or user interface 1260 in this condition to prevent further discharge of current to a device.

[0051] The controller 1210 can also monitor the temperature or voltage output of the battery 1230. In some examples, a battery temperature that is too high can indicate a state of overcharge and can result in battery failure. In this regard, the controller 1210 can compare a sensed battery temperature to a threshold battery temperature. If the sensed temperature is greater than the threshold temperature, the controller 1210 can activate a short circuit 1225 that at least temporarily directs current away from the battery to allow the temperature to return to a lower level. The threshold can be a predetermined threshold based on the selected battery 1230, or can be preset, stored in a lookup table, or can be determined by an algorithm.

[0052] The controller 1210 can also monitor the voltage output of the battery 1230. If the voltage output of the battery 1230 exceeds a first threshold voltage, the controller 1210 can activate a short circuit 1225 connected to the TEG 1220 to prevent any further charging of the battery. If the voltage output of the battery 1230 falls below a second threshold, which can be lower than the first threshold, the TEG 1220 may deactivate the short circuit 1225, thereby allowing current to charge the battery 1230 once again. The selection of first and second thresholds may be predetermined, or may be done according to look-up table or algorithm stored on a memory of the controller 1210. [0053] The battery 1230 can connect directly or indirectly to a boost circuit 1240, e.g., a boost convertor or a step-up circuit. The boost circuit 1240 can output a voltage that is greater than an output voltage of the battery 1230. In this regard, the output voltage of the boost circuit 1240 can be selected according to any number of factors, such as the voltage requirements of a connected device. Based on the selection of TEG 1220, battery 1230, and boost circuit 1240, the power output of the boost circuit 1240 can have a maximum output of 12 watts and can provide a continuous power output of approximately 8 watts. As discussed above, the power output of the system 1200 can be greatest when the hot side of the TEG approaches 400 F and the water in the kettle is boiling.

[0054] The boost circuit 1240 can be connected directly or indirectly to a port 1250.

The port 1250 can be any type of port, such as a USB port, micro-USB port, mini-USB port, or any other type of port capable of connecting to an electronic device. In other examples, the port 1250 can transmit data from the controller 1210, or a memory of the controller 1210, to an electronic device connected thereto. In yet another example, the port 1250 can be a conventional two or three-prong outlet.

[0055] The controller 1210 can also connect to a user interface 1260. The user interface can be any type of user interface, such as one or more status indicators, one or more audio alerts, a display device, a touch screen, or any other type of interface that can accept user input or indicate a status.

[0056] Fig. 13 depicts a first alternate embodiment wherein an illustrative packable electric generator 1300 has a flattened top surface 1302. The lower surface 1304 of the handle assembly 1306 is entirely flat and conforms to the top surface 1302.

[0057] Fig. 14 shows a second alternative embodiment wherein an illustrative packable electric generator 1400 is square in its horizontal profile. The top surface 1402 retains the shaped contour of the exemplary packable electric generator 100 above, and the handle assembly 1404 has the sane shape as the exemplary handle assembly 1 10 as set forth above.

[0058] Fig. 15 is a third alternate embodiment, wherein the bottom plate 1502 is shown in cross-section and a TEG 1504 is attached to the bottom plate 1502 by a supplemental fillet layer 1506 of thermal conductive epoxy glue in order to further optimize thermal transfer. The glue fillet layer 1506 can wholly replace the TEG bolts or augment them. The glue fillet layer 1506 can be mixed to improve the conductivity of thermal energy reaching the "cold" side 1508 of the TEG, thereby improving its performance. In other embodiments, the glue fillet layer 1506 functions as a resistor.

[0059] More generally, as used herein the directional terms, such as, but not limited to, "up" and "down", "upward" and "downward", "rearward" and "forward", "top" and "bottom", "inside" and "outer", "front" and "back", "inner " and "outer", "interior" and "exterior", "downward" and "upward", "horizontal" and "vertical" should be taken as relative conventions only, rather than absolute indications of orientation or direction with respect to a direction of the force of gravity.

[0060] The foregoing has been a detailed description of illustrative embodiments of the invention. Various modifications and additions can be made without departing from the spirit and scope of this invention. Features of each of the various embodiments described above may be combined with features of other described embodiments as appropriate in order to provide a multiplicity of feature combinations in associated new embodiments.

Furthermore, while the foregoing describes a number of separate embodiments of the apparatus and method of the present invention, what has been described herein is merely illustrative of the application of the principles of the present invention. For example, the geometry and volume of the packable electric generator can vary. The dimensions can vary. The sheet metal components can be replaced by composite materials, or high temperature resistant polymers. This description is meant to be taken only by way of example, and not to otherwise limit the scope of this invention.

[0061] What is claimed is:

Claims

CLAIMS 1. A packable electric generator comprising:

a hinged handle assembly comprising a top handle cover, a handle base, a port, a spring loaded on/off switch, a light-emitting diode display, a power storage battery, a wire array and a controller contained within the handle assembly;

a body housing assembly that is a vessel for containing a removable volume of liquid and for retaining the volume during heating, further comprising a top and co-formed outer perimeter wall having a hole and a hinge assembly;

a base sub-assembly comprised of a puck, an O-ring, a wire channel and a sheet metal vessel bottom; and

a TEG clamping sub-assembly comprising a thermal electric generator for generating electric power and a heat exchanger plate.

2. The packable electric generator of claim 1 further comprising an enclosed vessel for the heating of a volume of water that is a heat sink for a TEG that resides within the bottom of the vessel.

3. The packable electric generator of claim 1 further comprising a vessel containing a TEG that generates electricity as the vessel is heated.

4. The packable electric generator of claim 1 further comprising a handle wherein resides a power storage battery that is accessible for the withdrawal of stored power when the TEG is or is not generating power.

5. The packable electric generator of claim 1 further comprising a handle wherein the USB port is accessible for the withdrawal of electric power whether the TEG is generating electricity or the TEG is inactive.

6. The packable electric generator of claim 1 further comprising a vessel into which water can be inserted and removed.

7. The packable electric generator of claim 1 wherein the controller manages the power output and distribution.

8. The packable electric generator of claim 1 wherein the hot side of the TEG is in proximity to the heat exchanger plate and the cold side is in proximity to the puck.

9. The packable electric generator of claim 1 wherein the puck is an elevated cold side heat exchanger for the TEG.

10. The packable electric generator of claim 1 wherein the user interface determines when a level of the liquid contained in the vessel is low and gives a warning alert prior to overheating of the TEG.

11. The packable electric generator of claim 1 wherein the device is constructed and arranged wherein the wiring array is internal so as to be concealed from view and protected from thermal energy.

12. A method of charging an electronic device, comprising:

positioning a packable electric generator in proximity to a heat source, the packable electric generator having a volume for receiving a liquid configured to be heated by the heat source;

generating an electric current using the packable electric generator based in part on heat from the heat source;

charging a battery with the electric current;

powering the electronic device with the battery;

sensing an output voltage of the battery while powering the electronic device; and controlling the electric current generated by the packable electric generator based in part on the output voltage of the battery.

13. The method of claim 8, wherein controlling the electric current comprises activating a short circuit in the packable electric generator when the output voltage is above a first threshold.

14. The method of claim 9, wherein controlling the electric current further comprises deactivating a short circuit in the packable electric generator when the output voltage is below a second threshold.

15. A packable electric generator, comprising:

a body assembly comprising a thermal electric generator (TEG) and defining a volume configured to receive a liquid, the TEG being configured to generate an electric current based in part on a temperature of the liquid; and

a handle assembly operatively connected to the body assembly, the handle assembly comprising a rechargeable battery and a port configured to charge an electronic device.