Extruded Aluminum Coil Assembly for PCM Thermal Storage
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Solution Overview
Problem
Existing thermal energy storage systems are complex, costly, and require numerous welding points, leading to potential leaks and contamination of phase change materials, while traditional heat exchangers have high CO2 footprints and are not easily scalable.
Innovation Solution
A simplified thermal energy storage system with a U- or serpentine-shaped heat exchange coil made of aluminum, extruded for easy assembly and reduced welding, featuring a limited number of components and accessible design for maintenance, and utilizing phase change materials like water and hydrated salts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional heat exchangers are used in thermal energy storage systems, then heat exchange function is achieved, but device complexity increases and manufacturing cost increases
Solution Approach 1:
The patent combines the heat exchanger and thermal energy storage tank into a single integrated component. The heat exchanger is formed as a hollow coil directly within the tank, eliminating the need for separate heat exchanger assemblies, mounting brackets, and multiple welding points. This merging reduces device complexity and manufacturing cost while maintaining effective heat exchange functionality.
Solution Approach 2:
The hollow coil structure serves multiple functions simultaneously: it acts as the heat exchanger for thermal energy transfer, provides structural support within the tank, and serves as the container wall itself. This multi-functionality reduces the number of separate components needed, simplifying the overall system while maintaining all necessary functions.
2Reliability
If numerous welding points are used to assemble heat exchanger components, then heat exchange system is assembled, but reliability decreases due to increased leakage risk
Solution Approach 1:
By integrating the heat exchanger as a single hollow coil component within the tank, the patent eliminates multiple welding points that would otherwise be required to connect separate heat exchanger components to the tank. This merging approach maintains reliability by removing potential leakage paths while simplifying assembly to a single installation step.
3Use of energy by moving object
If heat exchange fluid is allowed to mix with phase change material, then thermal energy transfer occurs, but purity of phase change material decreases leading to reduced effectiveness
Solution Approach 1:
The hollow coil structure serves as a physical intermediary barrier between the heat exchange fluid and the phase change material. The coil walls provide thermal conduction for heat transfer while preventing direct contact and mixing between the two fluids. This intermediary structure maintains heat transfer efficiency through the coil walls while preserving the purity of the phase change material.
4Object-generated harmful factors
If aluminum is used instead of stainless steel for heat exchanger, then CO2 footprint decreases and heat transfer performance improves, but material selection is more limited
Solution Approach 1:
The patent specifies aluminum or aluminum alloy as the heat exchanger material, changing the material parameter from traditional stainless steel to aluminum. This parameter change reduces the CO2 footprint through more sustainable production processes and improves heat transfer performance through aluminum's higher thermal conductivity, while the design accommodates these material properties through appropriate corrosion protection and design considerations.
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 reduces maintenance costs, minimizes leakage risks, and offers a lower CO2 footprint with enhanced heat transfer performance, facilitating easy upscaling and integration in lightweight environments.
Implementation Method 1
The inner volume is, during operation, at least partly filled with a phase change material surrounding at least a part of the coil
Implementation Method 2
using aluminum instead of alternative heat exchanger materials, such as stainless steel, will yield a lower CO2 footprint for the overall heat exchanger thanks to available aluminum produced in CO2-free processes. Aluminum will also yield higher heat transfer performance, thanks its higher thermal conductivity.
Data Source
AI summary
The invention relates to a thermal energy storage system which includes a container with a phase change material (PCM) and a heat exchange coil interacting with the PCM. The coil is easy to produce and assemble within said system. The coil includes a plurality of internal channels for transporting a heat exchange fluid and provide a large surface area though which heat is transferred. The invention also relates to a method of manufacturing the coil by means of extrusion, and to a method of assembling said system.