Electrocaloric element, a heat transfer system comprising an electrocaloric element and a method of making them

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Solution Overview

Problem

Vapor compression refrigerant loops pose environmental hazards and are impractical in settings lacking a ready power source, and alternative cooling technologies like electrocaloric materials face challenges in scalability and mass production due to issues with fabricating electrically conductive electrodes.

Innovation Solution

An electrocaloric heat transfer system is developed by forming electrically conductive surface modifications on electrocaloric materials, thermally connecting them to heat sinks and sources, and electrically connecting them to a power source, with a controller to selectively apply voltage for coordinated heat transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If vapor compression refrigerant loops are used for cooling applications, then effective cooling and refrigeration can be provided, but environmental hazards such as ozone depleting potential and global warming potential arise

Engineering Contradiction:

Improvecooling effectivenessVSAvoidenvironmental hazards

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the mechanical vapor compression system with an electrocaloric system that uses electric field-induced phase transitions in electrocaloric materials to achieve cooling. This substitution eliminates refrigerants entirely, addressing the environmental hazard while maintaining cooling effectiveness through the electrocaloric effect where electric field application induces entropy change and temperature change in the material.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If vapor compression refrigerant loops are used in environments lacking sufficient power source, then cooling can be provided, but the power demand significantly shortens battery life or driving range

Engineering Contradiction:

Improvecooling capabilityVSAvoidpower demand

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent replaces the high-power mechanical compressor with an electrocaloric system that operates on low-power electrical fields. The electrocaloric materials undergo phase transitions when exposed to electric fields, producing cooling effects without requiring mechanical work. This substitution dramatically reduces power demand, making the system suitable for portable applications and electric vehicles where battery life and driving range are critical constraints.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If electrocaloric materials are fabricated into electrocaloric elements for heat transfer systems, then alternative cooling technology is achieved, but issues arise in fabricating electrically conductive electrodes

Engineering Contradiction:

Improvealternative cooling technologyVSAvoidelectrode fabrication

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent merges the electrode fabrication process with the electrocaloric material processing by forming conductive layers directly on the electrocaloric material surfaces during the same manufacturing sequence. This integration eliminates separate electrode fabrication steps, simplifying the overall manufacturing process and improving ease of production while maintaining the functional requirements of electrically conductive electrodes for applying electric fields to the electrocaloric material.

Inventive Principle:

Principle #5Merging (Combining)

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 approach enables efficient and scalable heat transfer while minimizing environmental impact and power requirements, overcoming the limitations of traditional refrigerant loops and bench-scale demonstrations of electrocaloric technologies.

Implementation Method 1

various technologies have been proposed such as field-active heat or electric current-responsive heat transfer systems relying on materials such as electrocaloric materials

Methodology Applied

Scientific EffectElectrocaloric effect: Electrocaloric Effect

Implementation Method 2

forming a first electrode at a first surface of the electrocaloric material, and forming a second electrode at a second surface of the electrocaloric material

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 3

thermally connecting the electrocaloric element to a heat sink along a first thermal flow path, thermally connecting the electrocaloric element to a heat source along a second thermal flow path

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS11598561B2Electrocaloric element, a heat transfer system comprising an electrocaloric element and a method of making them

Publication Date: 2023.03.07 CARRIER CORP

AI summary

A method of making an electrocaloric element includes providing an electrocaloric material, forming a first electrode at a first surface of the electrocaloric material, and forming a second electrode at a second surface of the electrocaloric material. The forming of the first electrode includes, or the forming of the second electrode includes, or the forming of each of the first and second electrodes independently includes modifying the respective first and/or second surface of the electrocaloric material with an electrically conductive surface modification.