Graded Polymer Heat Exchanger Wall for Low-GWP Refrigerants
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Solution Overview
Problem
Existing heat exchangers, particularly those using round tube plate fin (RTPF) or microchannel (MCHX) designs, are unsuitable for low Global Warming Potential (GWP) refrigerants due to size and pressure drop constraints, and metallic heat exchangers are heavy, posing issues in transport and aerospace applications, while polymer materials offer low thermal conductivity.
Innovation Solution
A heat exchanger utilizing functionally graded polymer composites with varying filler content to address thermal conductivity, mechanical strength, and permeability needs, tailored to specific parts, enabling the use of low-pressure refrigerants and reducing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If polymer materials are used to make heat exchangers, then weight is reduced and adaptability is improved, but thermal conductivity is insufficient
Solution Approach 1:
The patent employs composite materials by combining polymer base materials with thermally conductive fillers (such as metal particles, ceramic particles, or carbon-based materials) to create a composite polymer material that maintains the lightweight advantage of polymers while significantly improving thermal conductivity through the additive effect of conductive fillers
Solution Approach 2:
The patent applies local quality by creating functionally graded polymer composites where the filler concentration varies spatially within the material structure. Areas requiring higher thermal conductivity (such as regions adjacent to heat transfer surfaces) contain higher filler concentrations, while other areas maintain lower filler concentrations to preserve mechanical properties and processability, thus optimizing thermal performance where needed without compromising overall structure
2Temperature
If filler material is added to polymer to increase thermal conductivity, then thermal conductivity is improved, but mechanical strength and permeability deteriorate
Solution Approach 1:
The patent applies parameter changes by systematically varying the filler concentration, particle size distribution, and filler morphology to optimize the balance between thermal conductivity and mechanical strength. By controlling these parameters, the patent achieves sufficient thermal conductivity enhancement while maintaining adequate mechanical properties for heat exchanger application
Solution Approach 2:
The patent uses composite materials with carefully selected filler types and configurations to enhance thermal conductivity while minimizing negative impacts on mechanical strength. The selection of specific filler materials and their optimal concentrations allows simultaneous improvement of thermal performance and maintenance of structural integrity
3Ease of manufacture
If conventional heat exchangers are used, then manufacturing is straightforward, but they are not suitable for low GWP refrigerants due to size and pressure drop constraints
Solution Approach 1:
The patent applies parameter changes by modifying the physical and chemical properties of polymer materials to create heat exchangers with optimized thermal conductivity and flow characteristics specifically suited for low GWP refrigerants. This enables adaptation to new refrigerant types while maintaining the ease of manufacturing inherent to polymer-based systems
Solution Approach 2:
The patent achieves universality by developing polymer heat exchanger designs that can accommodate various low GWP refrigerant types and different application requirements. The functional grading approach allows the same basic structure to be optimized for different thermal and flow conditions, making the heat exchanger versatile across multiple refrigerant types and applications
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 solution results in low-cost, high-efficiency heat exchangers optimized for specific heat transfer needs, allowing the use of low-pressure refrigerants and reducing weight, while maintaining mechanical integrity.
Implementation Method 1
the polymer composite is tailored across the heat exchanger wall with varying filler content to balance thermal conductivity and mechanical strength
Data Source
Figure 1A
Figure 1B~1E
Figure 2
AI summary
A heat exchanger wall comprising: a first side (24), and a second side (26) opposite the first side, wherein the first side and the second side are comprised of a polymer composite, the polymer composite functionally graded across the heat exchanger wall from the first side to the second side.