Objective 2:
Build the TEG

Cadet, now that you have collected your tools and supplies, it’s time to start building your Chaos Dectector. The first step is to build the generator. This ain’t a normal generator, it’s thermoelectric! A thermoelectric generator (TEG) converts the flow of heat into electricity. In your case, the flow of heat will be body heat dissipating into the ambient air; the chaos that we naturally generate.

 

The TEG will consist of three thermoelectric modules stacked on top of each other, with a thermally conductive paste added in between to keep each module in physical contact with each other. All four edges of the TEG will be covered in silicone sealant to keep the modules in place. Then all three modules will be soldered electrically in series.

 

Let’s get started!

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1. Cadet, the first step in building the TEG is to physically attach 3x thermoelectic modules into one generator.

2. Now open the Chaos Dectector supply chest, and remove the three thermoelectric modules, the silicone sealant, and the thermal compound with the spreader.

3. Cadet, before you start connecting the thermoelectric modules together, test each module by placing your hand on top of it and measuring the voltage with a voltmeter. Notice how the voltage can either be positive or negative depending on which side of the module you are touching. The modules have polarity, like my mental state, so find the side that produces a positive voltage from the red wire. This will later be used when the generator is connected to the Chaos Dectector circuit board.

4. Alright cadet, we’re gonna make a Da Vinci out of you in no time. Let’s test those painting skills of yours. Things are gonna get messy, so take one of the modules and place it on a paper towel. Them add about 3-5mm of the tube of thermal compound to the module. Use a ruler to check how much the syringe on the thermal compound has moved from before to after using it. While holding the module down by its wires, use the spreader to spread the thermal compound across one side of the module like you’re painting the Mona Lisa. Make sure that it is evenly completely covered.

5. Next, take a second module with the same orientation and facing side as the first module (the red wires on one side and the black wires on the other side), and stack it on top. Then press down hard around the middle and edges like you’re squeezing out that last drop of toothpaste, until the thermal compound is coming out the sides. The two modules should be perfectly stacked. Then add some more thermal compound to the top of the second module. Like before, add about 3-5mm of the tube and use the spreader to evenly cover the module.

6. Then take a third module and stack it to the top of the second, exactly the same as before. Again, press down hard around the middle and edges until thermal compound is coming out the sides. Make sure the three modules are perfectly stacked like my mama’s pancakes. If thermal compound gets on your hands, no worries, it’s non-toxic, but you should not eat it. Just wipe it off with a paper towel and wash your hands.

7. Now clean the edges of the modules by wiping off excess thermal compound with pieces of paper towel. The sides of the stacked modules should be cleaner than your behind after using the toilet. You should be able to touch with only getting small amounts of thermal compound on ya. If any thermal compound gets on top of the module, just wipe it off with a paper towel.

8. Then wipe the spreader clean and pop open the tube of silicone sealant. Add silicone to the spreader and spread it across the sides of the stacked modules like icing on cake. All four sides of the modules should be covered in a thin layer of silicone. Then let it dry in an open space for about 2 hours.

9. After waiting 2 hours, breakfast is served. However, the silicone will not be fully cured, so it’ll feel a little sticky, but the modules should be stuck to each other like glue. So take the time to remove any excess silicone or thermal compound that might still be on the top or bottom of the TEG. If there’s any thermal compound stains on the module, they can be removed with isopropyl alcohol and a paper towel.

10. Alright cadet, it’s time to test those soldering skills. Take out your soldering iron, some solder, a pair of tweezers, and a pair of wire cutters and strippers.

11. The modules will be connected in series by diagonally soldering the red and black wires of adjacent modules. Set aside one red wire on the top module and one black wire on the bottom module. Do not cut these wires, or the TEG will exploded! Just kidding. The red wire will be the main output and the black wire will be the ground for the TEG. The wires that will be diagonally connected, should be cut with the wire cutter to a length of 1.5cm and 3cm. This means for one pair of wires, one black wire with a 1.5cm length will be soldered to a red wire with a length of 3cm. The second pair will have 3cm for the black wire and 1.5cm for the red wire. The center modules should have both wires cut to 1.5cm in length, and the outer modules should each have one 3cm wire. Use a ruler and a marker for accuracy.

12. Once all four wires are cut, strip about 0.5cm off the tips using an 18 gauge wire stripper. Keep caution when stripping the wires, as pulling too hard can separate the modules, leaving you with a sticky mess. It is recommended to hold the wire with one hand as you pull with the other. For the 1.5cm wires, wiggling them as you pull can make it easier to strip.

13. Next, twist the newly stripped ends and use the soldering iron to add solder to each individual tip. The tip should be completely covered in solder like a hot fudge Sunday.

14. Now, diagonally solder each 1.5cm/3cm pair by holding their tips with a pair of tweezers, and heating the overlapping tips with the soldering iron. This is only a recommendation because it can be a little tricky. As long as they’re soldered together, it is as good as done.

15. Once both pairs are soldered, press the wires down flat against the side of the generator, so that it’s within the thickness of the TEG.

16. Lastly, for good faith, you should check the TEG’s voltage by placing your hand on it. The voltage should be greater than what was measured with a single module. If it ain’t, you went wrong some where. Double check your soldering.