Method of making electrocaloric articles
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Solution Overview
Problem
Vapor compression refrigerant loops used in cooling technologies pose environmental hazards and are impractical in settings lacking a ready power source, such as electric vehicles, due to weight and power demands.
Innovation Solution
A method for manufacturing electrocaloric articles by applying a patterned disposition of conductive material to electrocaloric films, forming electrodes on the films, and integrating them into modules for efficient heat transfer systems, which can operate without mechanical compressors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If vapor compression refrigerant loops are used for cooling, then effective cooling and refrigeration can be provided, but environmental hazards such as ozone depleting potential and global warming potential occur
Solution Approach 1:
The patent replaces the mechanical vapor compression system with an electrocaloric system that uses electric fields to induce temperature changes in electrocaloric materials. This substitution eliminates the need for refrigerants and mechanical compressors, thereby resolving the environmental hazards while maintaining cooling effectiveness
Solution Approach 2:
The patent utilizes the electrocaloric effect where application of an electric field changes the temperature of the electrocaloric material. By controlling the electric field parameters (voltage, duration, frequency), the system achieves cooling without environmental harm, transforming the thermal state through electrical parameter changes rather than mechanical compression
2Temperature
If vapor compression refrigerant loops are used for cooling, then effective cooling can be provided, but the weight and power requirements of the compressor become problematic in portable applications
Solution Approach 1:
The patent replaces the heavy mechanical compressor with lightweight electrocaloric materials and simple electrode structures. The electrocaloric elements can be made from thin films or small components that are orders of magnitude lighter than traditional compressors, enabling portable and mobile cooling applications
Solution Approach 2:
The patent employs thin-film electrocaloric materials and flexible electrode structures that can be integrated into compact, portable devices. These thin-film components dramatically reduce the weight and size of the cooling system compared to traditional mechanical compressors
3Temperature
If vapor compression refrigerant loops are used for cooling, then effective cooling can be provided, but the power demand significantly shortens vehicle battery life or driving range
Solution Approach 1:
The patent replaces the high-power mechanical compressor with low-power electrocaloric actuators. The electrocaloric effect requires only electrical fields to induce temperature changes, consuming significantly less power than mechanical compression systems, thereby preserving battery life and driving range in electric vehicles
Solution Approach 2:
The patent utilizes periodic application of electric fields to the electrocaloric materials, where alternating electric fields induce cyclic temperature changes for continuous cooling. This periodic electrical actuation is far more energy-efficient than continuous mechanical compression, reducing overall power demand
4Temperature
If vapor compression refrigerant loops are used for cooling, then effective cooling can be provided, but the system becomes impractical in environments lacking a ready source of power
Solution Approach 1:
The patent replaces the mechanical compression system requiring substantial power infrastructure with an electrocaloric system that can operate on minimal electrical power sources. This substitution enables cooling functionality in remote, mobile, and power-limited environments where traditional vapor compression systems are impractical
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 cooling without environmental hazards and power source limitations, as electrocaloric materials can transfer heat using electric fields, reducing the need for refrigerants and mechanical components.
Implementation Method 1
electrocaloric materials can transfer heat using electric fields
Data Source
Figure 1
Figure 2
Figure 3A~3C
AI summary
A method of making an electrocaloric is disclosed. The method includes: (a) providing a roll of a film comprising an electrocaloric material or a supply of multiple sheets of a film comprising an electrocaloric material; (b) delivering film from the roll or the supply of multiple sheets to a conductive material application station; (c) forming electrodes comprising a patterned disposition of conductive material on the film at the application station to form an electrocaloric article (d) delivering film from the application station to a take-up roll or an inventory of electrocaloric sheets; and (e) repeating (b), (c), and (d) to form multiple electrocaloric articles.