3D Printed Lattice Heating Element for Ammonia Dissociation
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Solution Overview
Problem
Conventional electric catalyst units for ammonia dissociation are unsuitable for on-board vehicle applications due to their large size, high power requirements, limited surface area for heat absorption, susceptibility to failure in high temperature and pressure environments, and corrosion issues with metallic support structures.
Innovation Solution
A compact electric heating unit with a ceramic tube and a 3D printed lattice heating element, designed to efficiently dissociate ammonia, featuring a housing with a power feed-through, gas inlet, and outlet, where gaseous ammonia undergoes dissociation as it travels through the ceramic tube with the lattice structure, which is directly coupled to the power feed-through, allowing for efficient heat focusing and distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If conventional planar conductors are used for heating, then the device structure is simple, but the surface area is limited and cannot provide sufficient heat absorption for ammonia dissociation
Solution Approach 1:
The patent transitions from conventional two-dimensional planar conductors to three-dimensional lattice structures. The lattice heating element provides vastly increased surface area through its three-dimensional geometry, enabling sufficient heat absorption for ammonia dissociation while maintaining a compact form factor suitable for vehicle applications.
Solution Approach 2:
The lattice structure functions as a porous or highly surface-area material that maximizes the heating surface available for heat transfer. This porous-like structure allows the gas to interact with the heating element across multiple surfaces, dramatically improving heat absorption efficiency compared to solid planar conductors.
2Reliability
If metallic support structures are used in catalyst units, then the manufacturing is easier and structural strength is adequate, but the devices are susceptible to failure in high temperature, high pressure, and corrosive environments
Solution Approach 1:
The patent employs ceramic materials for the tube and support structures, creating a composite system that combines the high-temperature stability and chemical inertness of ceramics with the required structural functionality. This material selection provides resistance to thermal degradation, pressure, and corrosion from heated ammonia and hydrogen, while the 3D-printed lattice structure integrates manufacturing considerations.
Solution Approach 2:
The patent changes the material parameter from metallic to ceramic, fundamentally altering the thermal and chemical resistance properties. This material parameter change enables the device to operate reliably in high-temperature and corrosive environments where metallic supports would fail, while modern manufacturing techniques address the fabrication challenges.
3Power
If industrial AC voltage systems are used for ammonia dissociation, then the heating power is sufficient, but the system size and weight become too large for vehicle on-board applications
Solution Approach 1:
The patent applies local quality by concentrating heating power density through the 3D lattice structure. The distributed lattice elements provide intensive local heating throughout the gas flow path, achieving effective ammonia dissociation with lower overall power requirements compared to conventional industrial systems, thereby reducing system weight for vehicle applications.
Solution Approach 2:
The three-dimensional lattice structure provides vastly increased surface area and heat transfer pathways within a compact volume. This dimensional transformation enables high heating efficiency and power density in a space-constrained application, allowing vehicle on-board installation without requiring large industrial-scale components.
4Reliability
If conventional catalytic converters are used, then the device is simple and easy to manufacture, but they cannot contain significant pressure and are not hermetically sealed
Solution Approach 1:
The patent uses ceramic materials for the tube and housing structures, which provide inherent pressure containment and hermetic sealing capabilities. The ceramic material's mechanical strength and chemical stability enable the device to withstand high pressures and maintain sealed conditions, preventing leakage of heated ammonia and hydrogen, while the 3D-printed lattice structure integrates with these containment requirements.
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 enables efficient ammonia dissociation on-board vehicles by maintaining high temperatures necessary for the endothermic reaction while withstanding high temperature, pressure, and corrosive conditions, ensuring reliable operation and minimizing the risk of component failure.
Implementation Method 1
a heating element having a lattice structure disposed within the ceramic tube, the heating element directly coupled to the power feed-through
Implementation Method 2
The ammonia dissociation reaction is highly endothermic
Data Source
AI summary
The present invention relates, in general, to a system and method for focusing gas distribution through a series of three-dimensionally (3D) printed lattice heating elements within an electric catalyst unit in order to promote ammonia dissociation. The present invention allows gaseous ammonia to be continuously heated as it flows in series through ceramic tubes containing 3D printed lattice heating elements. The lattice structure of the heating elements provides a balance between surface area and heat dissipation, allowing the heating elements to reach a suitable temperature to perform ammonia dissociation, but which are not oversaturated with heat which could result in failure or melting of the heating elements.