Extruded Magnetocaloric Blade Array for Scalable Heat Exchange
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Solution Overview
Problem
Conventional refrigeration techniques are inefficient and environmentally harmful, while existing magnetic refrigeration technologies face challenges in achieving optimal heat exchange due to limitations in the geometry of magnetocaloric materials, which restricts the scalability and efficiency of cold production.
Innovation Solution
A one-piece part made from magnetocaloric materials with optimized dimensions and geometry, featuring a base and blades with specific ratios and configurations, optimized for enhanced heat exchange, manufactured using an extrusion process to achieve precise and reproducible dimensions, allowing for improved thermal performance and mass production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional refrigeration techniques are used, then refrigeration function is provided, but energy efficiency is insufficient and environmental harm occurs
Solution Approach 1:
The patent replaces the conventional mechanical compression-expansion refrigeration system with a magnetic field-based refrigeration system. The magnetocaloric material undergoes magnetization and demagnetization cycles to absorb and release heat, eliminating the need for compressors, refrigerant gases, and associated mechanical components, thereby improving energy efficiency and eliminating environmental harm.
Solution Approach 2:
The patent utilizes the magnetocaloric phase transition of the magnetocaloric material, which changes its magnetic state between magnetized and demagnetized conditions. During magnetization, the material releases heat; during demagnetization, it absorbs heat. This phase transition mechanism enables efficient heat transfer and refrigeration without harmful refrigerants.
2Productivity
If magnetocaloric materials with optimized geometry are used, then heat exchange efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The magnetocaloric material is divided into multiple thin blades or plates arranged in a stacked configuration. This segmentation increases the surface area available for heat exchange with the heat transfer fluid, significantly improving heat exchange efficiency. The segmented structure also allows the heat transfer fluid to flow through channels between the blades, enhancing thermal contact.
Solution Approach 2:
The patent combines the magnetocaloric material blades with integrated positioning elements and support structures into a unified assembly. The blades are positioned at precise intervals using built-in positioning features, merging multiple functional components (heat exchange surfaces, spacing elements, support structures) into a single integrated unit that simplifies manufacturing and assembly while maintaining optimized heat exchange geometry.
3Manufacturing precision
If precise positioning elements are added to control blade distances, then heat exchange characteristics are improved, but device complexity increases
Solution Approach 1:
The positioning elements are integrated directly into the blade structure or support framework, combining the functions of structural support, spacing control, and alignment into unified components. This integration eliminates the need for separate positioning mechanisms while maintaining precise blade spacing for optimal heat exchange characteristics.
Solution Approach 2:
The positioning elements are designed to automatically maintain precise blade spacing through self-aligning features such as complementary geometric shapes, elastic deformation, or thermal expansion differences. The structure itself provides the positioning function without requiring external adjustment mechanisms, simplifying the overall device while ensuring manufacturing precision.
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 optimized geometry and manufacturing process enhance heat exchange efficiency, enabling higher thermal power delivery and reducing energy consumption, while being cost-effective for industrial applications.
Implementation Method 1
This method relies on the magnetocaloric effect (MCE) of certain materials, which involves a change in their temperature when subjected to a magnetic field.
Implementation Method 2
During these magnetic phases, the material is traversed by the liquid called heat transfer fluid which will either heat up in contact with the material during a phase called magnetization, or cool down in contact with the material during a phase called demagnetization.
Data Source
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AI summary
The invention relates to a one-piece part containing a magnetocaloric material not including an alloy including iron and silicon and a lanthanide, characterized in that: said part comprises a base located in a first plane defined by a first direction (Dx) and a second direction (Dy), and a set of N unit blades (La,i) rigidly connected to said base; said blades have a first dimension (D Lai,x) in the first direction, a second dimension (D Lai,y) in the second direction and a third dimension (D Lai, z) in a third direction (Dz) perpendicular to the first and second directions; an ith blade is separated from an (i+1)th blade by an ith distance (d i); the ratio between the second dimension and the first dimension is greater than or equal to 10; the ratio between the third dimension and the first dimension is greater than or equal to 6; and the first dimension is of the same order of magnitude as said distance between an ith blade and an (i+1)th blade. The invention also relates to a heat generator comprising the one-piece parts of the invention.