Multi-material-blade for active regenerative magnetocaloric or electro-caloric heat engines
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Solution Overview
Problem
Existing active regenerative magneto-caloric and electro-caloric heat engines face limitations such as low operating speed, high pressure drops, low packing density, and significant losses due to packed bed structures, making them inefficient and costly for commercial applications.
Innovation Solution
A Multi-Material-Blade design with stacked elements made from different magneto-caloric or electro-caloric materials, separated by spacers to form dedicated channels, optimized for high packing density, reduced thermal conductivity, and minimized losses, using materials with varying Curie temperatures to match temperature gradients and minimize local losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a packed bed structure is used in active regenerative magneto-caloric or electro-caloric heat engines, then the device can be assembled with simple geometry, but it results in low operating speed and high pressure drops
Solution Approach 1:
The regenerator is divided into multiple discrete channels with structured flow paths instead of a continuous packed bed. This segmentation allows the exchange fluid to follow defined routes through the magneto-caloric material, reducing turbulence and pressure drops while enabling higher operating speeds.
Solution Approach 2:
The patent introduces a rotating or movable blade structure that dynamically adjusts the flow channels and magnetic field exposure. This dynamic configuration optimizes the interaction between the exchange fluid, magneto-caloric material, and magnetic field at different operational phases, significantly improving operating speed compared to static packed bed designs.
2Device complexity
If a packed bed structure is used, then the device structure is simple, but it causes high pressure drops and significant losses
Solution Approach 1:
The patent introduces carefully designed flow channels and spacing structures as intermediaries between the magneto-caloric material and the exchange fluid. These intermediaries guide the fluid flow in a controlled manner, reducing turbulence and pressure drops while maintaining effective heat exchange, thereby minimizing energy losses.
Solution Approach 2:
The patent optimizes geometric parameters such as channel dimensions, blade spacing, and magneto-caloric material configuration to minimize pressure drops. By carefully adjusting these parameters, the system reduces flow resistance and energy losses while maintaining structural simplicity.
3Device complexity
If uniform magneto-caloric material is used throughout the regenerator, then the structure is simple, but it results in significant local losses due to mismatched temperature gradients
Solution Approach 1:
The patent implements a multi-material blade structure where different sections of the blade contain different magneto-caloric materials with specific Curie temperatures tailored to local temperature conditions. This local optimization ensures that each material operates at its optimal temperature range, minimizing local losses and maximizing overall efficiency.
Solution Approach 2:
The regenerator uses composite structures combining multiple magneto-caloric materials with different Curie temperatures in a single blade assembly. This composite approach allows the system to handle wider temperature ranges efficiently, with each material contributing to heat exchange in its optimal temperature window, thereby reducing local losses.
4Volume of stationary object
If the regenerator is designed for high packing density, then the device size is reduced, but it increases pressure drops and reduces operating speed
Solution Approach 1:
The patent employs a nested channel structure where multiple flow paths are arranged concentrically or in layered configurations within the blade. This nesting allows high packing density of magneto-caloric material while maintaining open, unobstructed flow channels that minimize pressure drops and enable high operating speeds.
Solution Approach 2:
The patent utilizes three-dimensional channel configurations and spatial arrangements that optimize both packing density and flow characteristics. By designing channels that extend in multiple dimensions and utilizing the full volumetric space efficiently, the system achieves compact size without compromising operating speed.
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 design achieves higher temperature gradients, reduced losses, and increased efficiency, enabling compact, high-speed, and cost-effective operation of the heat engines.
Implementation Method 1
Magneto-caloric materials exhibit the magneto-caloric effect (MCE), which is the change in temperature upon the application or removal of a magnetic field
Implementation Method 2
Electro-caloric materials exhibit the electro-caloric effect (ECE), which is the change in temperature upon the application or removal of an electric field
Implementation Method 3
BC and DA is accomplished through heat exchange between the magneto-caloric-material and an exchange fluid
Data Source
Figure 1a~1b
Figure 2a
Figure 2b
AI summary
The present invention describes the design and fabrication of Multi-Material-Blades used as active regenerative regenerators in active regenerative magneto-caloric or electro-caloric engines. The blades consist of a plurality of elements (2) that divide the blade body along its length. Each element (2) is made of a different magneto-caloric or electro-caloric material selected appropriately, and a plurality of dedicated channels (3) penetrates the blade body (1) and extends along the length of the blade. Further, each of the plurality of elements (2) is rotated in the blade body (1) in respect to its adjacent elements (2). These measures can improve the performance of active regenerative magneto-caloric or electro-caloric engines, and lay the basis for commercial solutions.