Multi-material-blade for active regenerative magneto-caloric or electro-caloric heat engines
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Solution Overview
Problem
Current active magnetic regenerative (AMR) and electro-regenerative (AER) heat engines face limitations in operating speed, packing density, pressure drops, and cooling power due to the use of packed bed structures, which result in high costs and large sizes, and require optimization of material selection and geometry to enhance performance and efficiency.
Innovation Solution
A Multi-Material-Blade design featuring a blade body divided into elements made from different magneto-caloric or electro-caloric materials with dedicated channels and varying porosity regions, optimized for high packing density, reduced pressure drops, and enhanced cooling capacity, utilizing materials like LaFeSi and P(VDF-TrFE-chlorofluoroethylene with specific Curie temperatures and porosity levels to maximize temperature gradients and cooling capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If packed bed structures are used in AMR/AER heat engines, then the engines can achieve basic cooling function, but the operating speed is limited and the device size and cost increase
Solution Approach 1:
The blade is divided into multiple elements made from different magneto-caloric or electro-caloric materials, each with specific Curie temperatures and porosity levels. This segmentation allows optimization of heat exchange at different temperature zones, enabling faster operating speeds while reducing the overall device volume through more efficient material utilization.
Solution Approach 2:
Different regions of the blade body have different porosity values optimized for their local thermal and flow requirements. The porosity varies along the blade length to match the temperature gradient and heat exchange demands at different positions, improving overall performance while compacting the device structure.
2Power
If packed bed structures are used in AMR/AER heat engines, then the engines can achieve basic cooling function, but pressure drops increase and cooling power decreases
Solution Approach 1:
The blade elements incorporate porous magneto-caloric or electro-caloric materials with controlled porosity (20-80%) to enhance heat exchange surface area while maintaining low pressure drop characteristics. The porous structure allows efficient heat transfer between the caloric material and exchange fluid without creating excessive flow resistance.
Solution Approach 2:
The porosity parameter is varied across different blade elements to optimize the balance between heat exchange efficiency and pressure drop. Elements closer to the heat exchange zones have higher porosity for better heat transfer, while elements in the temperature gradient zones have lower porosity to maintain structural integrity and reduce pressure losses.
3Temperature
If single-material blades are used, then the manufacturing is simpler, but the temperature gradient and cooling capacity are reduced
Solution Approach 1:
Different blade elements are made from different magneto-caloric or electro-caloric materials with specific Curie temperatures matched to their local operating temperature ranges. This local material optimization creates an optimized temperature gradient across the blade, maximizing cooling capacity while managing the complexity through systematic material selection.
Solution Approach 2:
The blade functions as a composite structure combining multiple caloric materials, each contributing its unique thermal and magnetic/electric properties. This composite approach enables the blade to handle wider temperature ranges and achieve higher temperature gradients than single-material designs, with the complexity managed through modular element design.
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 Multi-Material-Blade design significantly increases the temperature gradient and cooling capacity of active regenerative engines, reduces losses, and enables more compact, cost-effective solutions by optimizing material selection and geometry, thereby improving the efficiency and performance of magneto-caloric and electro-caloric 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
When the exchange fluid is cyclically blown between the two ends of the AMR, and the magnetic field is applied and removed with the same periodicity, a temperature gradient is established between the cold end side and the hot end side of the AMR
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. The dedicated channels (3) can be provided with fluid mixing structures, porous layers or hydrophobic coatings to reduce the HE loss in an active regenerative engine. The Multi-Material-Blades are obtainable by ink jet printing techniques to reduce costs. The Multi- Material-Blades can further have a curved shape to form an involute blade body (1). All measures can improve the performance of active regenerative magneto-caloric or electro-caloric engines, and lay the basis for commercial solutions.