Monolithic Heater Body With Conduction Breaks for Lower Thermal Loss
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Solution Overview
Problem
Current power generation and distribution systems face challenges in achieving improved power generation efficiency, reduced emissions, and increased power density, particularly in closed-cycle engines like Stirling engines, due to inefficiencies such as inefficient combustion, heat exchangers, and mass transfer issues.
Innovation Solution
The development of a monolithic heat exchanger body using additive manufacturing techniques, which eliminates seams and joints, allowing for more efficient heat transfer and reduced thermodynamic losses, and the integration of a recirculation pathway with a hot-side heat exchanger and eductor to enhance combustion efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional heat exchangers with seams and joints are used, then manufacturing is easier, but heat transfer efficiency decreases and thermodynamic losses increase
Solution Approach 1:
The patent combines multiple heat exchanger components into a single monolithic body formed by additive manufacturing. This eliminates the need for separate parts connected by seams or joints, thereby reducing thermal losses at interfaces while maintaining manufacturing feasibility through advanced additive processes.
2Productivity
If closed-cycle engines use conventional heat exchangers, then device complexity is lower, but power generation efficiency and power density are reduced
Solution Approach 1:
The patent utilizes additive manufacturing technology to create complex internal geometries and optimized heat transfer surfaces that cannot be achieved with traditional manufacturing. This enables improved heat transfer coefficients and thermal efficiency while the monolithic integration actually reduces overall device complexity by eliminating multiple components.
3Object-generated harmful factors
If heat exchangers with seams and joints are used, then manufacturing is simpler, but heat transfer efficiency and combustion efficiency deteriorate
Solution Approach 1:
The monolithic heat exchanger body integrates combustion chamber, heat exchanger, and recirculation pathway into a single seamless structure. This eliminates leakage paths and improves combustion efficiency, reducing harmful emissions while the additive manufacturing process makes this complex integration feasible.
4Power
If conventional heat exchanger designs are used, then device complexity is reduced, but power density and efficiency are lowered
Solution Approach 1:
The additive manufacturing process enables three-dimensional optimization of heat transfer surfaces and internal flow paths within the monolithic body. This dimensional freedom allows for enhanced heat transfer area and optimized fluid dynamics, increasing power density while the integrated design reduces overall system complexity.
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 solution improves power generation efficiency, reduces emissions, and increases power density by optimizing heat transfer and combustion processes within closed-cycle engines, leading to enhanced performance and reliability.
Implementation Method 1
The plurality of heating fluid pathways may be circumferentially spaced about an inlet plenum... The hot-side heat exchanger body may be additively manufactured
Implementation Method 2
The recirculation pathway may include a hot-side heat exchanger... transferring heat from the combustion gas to the working fluid
Implementation Method 3
The recirculation pathway with a hot-side heat exchanger and eductor to enhance combustion efficiency
Data Source
Figure 4.1.1
Figure 4.1.2A
Figure 4.1.2B
AI summary
A monolithic heat exchanger body (c600) includes a plurality of heating walls (c616) configured and arranged in an array of spirals or spiral arcs relative to a longitudinal axis (c204), and plurality of combustion fins (c450) circumferentially spaced about a perimeter of an inlet plenum (c604). Adjacent portions of the heating walls (c616) respectively define a heating fluid pathway (c602) that fluidly communicate with the inlet plenum (c604). The combustion fins (c450) occupy a radially or concentrically inward portion of the monolithic heat exchanger body (c600). The heating fluid pathways (c602) have a heat transfer relationship with a heat sink (c409) disposed about a radially or concentrically outward portion of the monolithic heat exchanger body (c600). A plurality of conduction breaks (c605) disposed radially or concentrically outward relative to the plurality of combustion fins (c450) at least partially inhibit heat conduction from the plurality of combustion fins (c450) to the plurality of heating walls (c616).