Caloric heat pump system

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Solution Overview

Problem

Conventional refrigeration heat pump systems using fluid refrigerants face inefficiencies, environmental concerns, and impracticality across varying ambient temperatures, limiting their effectiveness and cost competitiveness, especially for appliance refrigeration.

Innovation Solution

A caloric heat pump system utilizing non-circular gears and a regenerator housing with a motor, where a caloric material is positioned within the housing and rotated relative to a field generator, allowing for efficient heat transfer through the magneto-caloric effect, enabling the system to operate effectively across a range of temperatures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If conventional fluid refrigerant heat pump systems are used, then the systems can transfer heat energy effectively, but the systems operate at only about forty-five percent or less of the maximum theoretical Carnot cycle efficiency

Engineering Contradiction:

ImproveCarnot cycle efficiencyVSAvoidenergy loss

Core Design Contradiction:

Use of energy by moving objectVSLoss of energy

Solution Approach 1:

The patent transitions from fluid refrigerant-based heat transfer to solid-state magneto-caloric material-based heat transfer. The magneto-caloric material undergoes parameter changes in magnetic field strength to induce temperature changes, enabling operation at significantly higher Carnot cycle efficiency compared to conventional fluid refrigerant systems.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the mechanical compression and expansion of fluid refrigerant with a magnetic field-based system. The magneto-caloric material is moved into and out of magnetic fields generated by magnets, eliminating the need for mechanical compressors and enabling more efficient heat transfer.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Use of energy by moving object

If magneto-caloric materials are used in heat pump systems, then the theoretical Carnot cycle efficiency can be significantly higher, but the equipment may require relatively large and expensive magnets

Engineering Contradiction:

ImproveCarnot cycle efficiencyVSAvoidcost competitiveness

Core Design Contradiction:

Use of energy by moving objectVSEase of manufacture

Solution Approach 1:

The patent divides the magneto-caloric material into multiple discrete stages positioned at different radial distances from the rotation axis. This segmentation allows different portions of the material to experience different magnetic field strengths, optimizing the overall system efficiency while reducing the size and cost requirements of individual magnets.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs non-circular gears with asymmetric tooth profiles to convert rotational motion into the reciprocating motion needed for moving magneto-caloric material through magnetic fields. This asymmetric mechanism enables efficient heat pump operation with more compact and cost-effective magnet configurations.

Inventive Principle:

Principle #4Asymmetry

3Use of energy by moving object

If magneto-caloric materials are used in heat pump systems, then higher efficiency can be achieved, but the equipment may be impractical for use in appliance refrigeration

Engineering Contradiction:

ImproveCarnot cycle efficiencyVSAvoidpracticality for appliance refrigeration

Core Design Contradiction:

Use of energy by moving objectVSEase of operation

Solution Approach 1:

The patent creates a dynamic system where magneto-caloric material stages are continuously moved into and out of magnetic fields through rotation. This dynamic operation, enabled by non-circular gears and a rotating regenerator housing, allows the system to achieve high efficiency while maintaining a compact form factor suitable for appliance refrigeration.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent positions multiple stages of magneto-caloric material within a rotating regenerator housing, with each stage nested at different radial distances from the rotation axis. This nested configuration allows efficient use of space and enables the system to fit within compact appliance refrigeration environments.

Inventive Principle:

Principle #7Nested doll (Nesting)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The system achieves higher theoretical Carnot cycle efficiency and cost competitiveness by efficiently moving caloric materials in and out of a magnetic field, enhancing heat transfer and operational efficiency in appliances and other applications.

Implementation Method 1

Magneto-caloric materials (MCMs), i.e. materials that exhibit the magneto-caloric effect, provide a potential alternative to fluid refrigerants for heat pump applications. In general, the magnetic moments of an MCM will become more ordered under an increasing, externally applied magnetic field and cause the MCM to generate heat. Conversely, decreasing the externally applied magnetic field will allow the magnetic moments of the MCM to become more disordered and allow the MCM to absorb heat.

Methodology Applied

Scientific EffectMagneto-caloric effect: Magnetocaloric Effect

Data Source

PatentUS10281177B2Caloric heat pump system

Publication Date: 2019.05.07 HAIER US APPLIANCE SOLUTIONS INC

AI summary

A caloric heat pump system includes a motor and a pair of non-circular gears meshed with each other. A first one of the pair of non-circular gears is coupled to a regenerator housing, and a second one of the pair of non-circular gears is coupled to the motor. The regenerator housing is rotatable with the motor through the pair of non-circular gears.