Electrically Conductive Brickwork Module for Use as a Heating and/or Thermal Storage System

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Solution Overview

Problem

Traditional electrically conductive firebrick systems face issues with chromium oxide volatilization, leading to erosion of electrical performance and the production of toxic gases, which complicates thermal energy storage and heating applications.

Innovation Solution

The electrically conductive brickwork module is designed with a configuration of electrically insulating columns and interconnected conductive bricks, where fluid flow paths are separated from the conductive bricks to prevent direct air contact and volatilization, thereby maintaining electrical performance and reducing toxic gas production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If air/gas flows straight over the conductive bricks to extract heat, then heat extraction efficiency is improved, but chromium oxide volatilization occurs causing erosion of electrical performance and toxic gas production

Engineering Contradiction:

Improveheat extraction efficiencyVSAvoidelectrical performance stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system is segmented into distinct functional zones: conductive bricks for heating, insulating bricks for thermal management, and flow channels for gas extraction. This segmentation allows heat extraction while preventing direct contact between gas and conductive brick surfaces, reducing chromium oxide volatilization.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Electrically insulating bricks are introduced as intermediary elements between the conductive bricks and the flowing gas. These insulating bricks prevent direct contact between the gas and conductive bricks, thereby preventing chromium oxide volatilization while still allowing heat transfer through radiation and conduction.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Use of energy by moving object

If air/gas flows straight over the conductive bricks, then thermal energy transfer is improved, but toxic gas (CrO3) is produced that must be kept below regulated levels

Engineering Contradiction:

Improvethermal energy transferVSAvoidtoxic gas production

Core Design Contradiction:

Use of energy by moving objectVSObject-generated harmful factors

Solution Approach 1:

Electrically insulating bricks serve as intermediary barriers that prevent direct contact between the flowing gas and conductive bricks. This intermediary layer eliminates the chemical reaction between oxygen in the gas and chromium oxide in the bricks, preventing toxic CrO3 gas production while maintaining thermal energy transfer through the insulating material.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The insulating bricks, which might seem to reduce direct heat transfer efficiency, actually prevent the harmful chemical reaction and toxic gas production. The thermal energy is still effectively transferred through radiation and conduction pathways, converting a potential harm (direct contact) into a benefit (toxicity prevention).

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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

This configuration effectively enhances the longevity of electrical performance and minimizes toxic gas production, allowing for reliable and efficient thermal energy storage and heating without the need for fossil fuels.

Implementation Method 1

a plurality of electrically interconnected conductive bricks disposed in each insulating column through the hollow central regions of the electrically insulating bricks and the plurality of electrically interconnected conductive bricks configured to be heated when electricity flows there through

Methodology Applied

Scientific EffectResistive heating: Joule Heating

Implementation Method 2

at least one flow path from the input to the output of the electrically conductive brickwork module formed by a gap between at least two of the plurality of electrically insulating columns configured to direct a fluid flowing from the input to the output without the fluid physically contacting the plurality of electrically conductive bricks

Methodology Applied

Scientific EffectFluid flow through gaps: Convection

Implementation Method 3

a plurality of electrically insulating columns, each formed of a plurality of electrically insulating bricks

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS20250052516A1Electrically Conductive Brickwork Module for Use as a Heating and/or Thermal Storage System

Publication Date: 2025.02.13 ELECTRIFIED THERMAL SOLUTIONS INC

AI summary

An electrically conductive brickwork module configured to be used in an electrically heated thermal energy storage system and/or a resistive heating system to heat a fluid flowing across a dimension of the electrically conductive brickwork module from an input to an output. The module includes a plurality of electrically interconnected sets of electrically conductive bricks configured to be heated when electricity flows there through and a plurality of electrically insulating bricks separating each pair of adjacent sets of the plurality of electrically interconnected sets. There are and a plurality of flow paths defined by the plurality of electrically insulating and physically separated from the electrically conductive bricks to direct a fluid flowing from the input to the output.