Method of fabricating an article for magnetic heat exchanger
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Solution Overview
Problem
Current methods for fabricating working components for magnetic heat exchangers are not cost-effective and scalable for industrial applications, limiting the widespread adoption of magnetic heat exchange technology.
Innovation Solution
The method involves arranging elongated articles with a magnetocalorically active phase in a specific orientation within the working component, where the shortest axes are parallel to each other, to reduce turbulence and enhance heat exchange efficiency, using techniques such as magnetic alignment, adhesive securing, or reactive sintering, and employing binders like poly(alkylene carbonate) to maintain mechanical integrity and minimize chemical reactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If magnetocalorically active material is provided in the form of particles or plates for practical working components, then the magnetic heat exchange function is achieved, but the fabrication cost increases and industrial scalability is limited
Solution Approach 1:
The working component is segmented into multiple elongated articles with specific aspect ratios (l≥1.5s). This segmentation allows for standardized manufacturing of individual articles that can be assembled into larger working components, improving both fabrication efficiency and industrial scalability while maintaining the magnetic heat exchange function.
Solution Approach 2:
The invention specifies particular geometric parameters for the elongated articles, including aspect ratio (l≥1.5s) and orientation angles relative to coolant flow direction. These parameter specifications enable standardized manufacturing processes and facilitate industrial-scale production while ensuring optimal heat exchange performance.
2Productivity
If articles are arranged with longest axis parallel to coolant flow direction, then heat exchange efficiency increases, but manufacturing precision requirements increase
Solution Approach 1:
The invention employs asymmetric elongated articles with aspect ratio l≥1.5s, where the distinctive long-axis geometry provides natural alignment cues during assembly. This asymmetric shape makes it easier to achieve the required orientation (longest axis parallel to coolant flow) compared to symmetric particles, thereby reducing manufacturing precision requirements while maintaining high heat exchange efficiency.
Solution Approach 2:
The elongated articles are pre-formed with specific geometric characteristics (aspect ratio l≥1.5s) before assembly into the working component. This preliminary shaping ensures that during assembly, the articles naturally align in the correct orientation relative to coolant flow, reducing the precision requirements during the final assembly process.
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 improves heat exchange efficiency by reducing turbulence and demagnetizing fields, increasing the mechanical integrity of the working component, and maintaining the magnetocaloric properties while being cost-effective and suitable for industrial-scale production.
Implementation Method 1
The magnetocaloric effect describes the adiabatic conversion of a magnetically induced entropy change to the evolution or absorption of heat. Therefore, by applying a magnetic field to a magnetocalorically active working material, an entropy change can be induced which results in the evolution or absorption of heat.
Implementation Method 2
Elongate forms including magnetocalorically active material are useful for working components of a magnetic heat exchanger since they can be arranged such that the longer axis or dimension is substantially parallel to the direction of the flow of the coolant and the shortest axis is substantially perpendicular to the direction of flow of coolant. This arrangement reduces turbulence in the coolant flow and increases heat exchange between the working component and the coolant.
Implementation Method 3
The binder may be selected to avoid undesirable chemical reactions with the magnetocalorically active phase or elements or precursors of the magnetocalorically active phase and/or to reduce the uptake of elements from the binder, for example carbon and/or oxygen, into the magnetocalorically active phase which may affect the magnetocaloric properties.
Data Source
AI summary
In an embodiment, a method of fabricating a working component for magnetic heat exchange comprises arranging at least two articles comprising a magnetocalorically active phase and an elongated form with a long axis having a length l and a shortest axis having a length s, wherein l≥1.5 s, such that the shortest axes of the at least two articles are substantially parallel to one another and securing the at least two articles in a position within the working component such that the shortest axes of the at least two articles are substantially parallel to one another within the working component.