PCM Thermal Exchanger Layout for Heat Storage and Fluid Exchange
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Solution Overview
Problem
Thermal exchangers face challenges in optimizing heat exchange and thermal energy storage, particularly when a fluid's temperature change is influenced more by the storage material than by exchange with another fluid, leading to inefficient thermal management and unnecessary energy loss.
Innovation Solution
A thermal exchanger design with divided fluid channels and interposed thermally conductive walls containing phase change materials (PCMs) for energy storage, along with additional hollow conductive walls for direct fluid-to-fluid heat exchange, optimized for efficient thermal energy transfer and reduced weight through corrugated metal plates and a thermally insulating housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a single fluid channel is used with PCM storage walls, then thermal energy storage function is provided, but heat exchange efficiency between fluids is reduced
Solution Approach 1:
The single fluid channel is segmented into multiple parallel sub-channels (first sub-channel and second sub-channel) with PCM storage walls interposed between them. This segmentation allows the first fluid to exchange heat with PCM in one sub-channel while simultaneously enabling heat exchange between first and second fluids through additional thermally conductive walls in other sub-channels, thereby resolving the contradiction between thermal energy storage and heat exchange efficiency.
Solution Approach 2:
The thermal exchanger is designed to perform multiple functions simultaneously: thermal energy storage through PCM materials in some sub-channels, and direct fluid-to-fluid heat exchange through additional thermally conductive walls in other sub-channels. This multi-functionality allows the system to adapt to different thermal management needs without sacrificing either energy storage or exchange efficiency.
2Use of energy by moving object
If PCM material is interposed between all fluid channels, then thermal energy storage is optimized, but direct fluid-to-fluid heat exchange is prevented
Solution Approach 1:
The fluid channels are segmented into distinct groups: some sub-channels have PCM storage walls interposed for thermal energy storage, while other sub-channels have additional thermally conductive walls without PCM for direct fluid-to-fluid heat exchange. This segmentation allows simultaneous optimization of both thermal energy storage and heat exchange rate through different channel configurations.
3Ease of manufacture
If traditional plate fabrication methods are used, then manufacturing is simple, but structural rigidity and heat exchange surface area are limited
Solution Approach 1:
The plates are fabricated with corrugated surfaces featuring undulating patterns of peaks and valleys. This curvature increases the surface area for heat exchange while the corrugated structure inherently provides structural rigidity. The corrugations are formed through conventional stamping processes, maintaining manufacturing simplicity while achieving enhanced structural and thermal performance.
4Ease of manufacture
If flat plates are used without corrugations, then manufacturing is easier, but heat exchange surface area and fluid guidance are insufficient
Solution Approach 1:
Corrugated surfaces with undulating patterns are formed on the plates through stamping processes. This curvature transformation significantly increases the heat exchange surface area compared to flat plates, while the corrugated structure also serves to guide fluid flow through the channels. The manufacturing process remains relatively simple as it uses conventional stamping techniques.
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 design enhances thermal management by allowing efficient heat exchange between fluids, optimizing energy storage and transfer, while minimizing weight and material usage, suitable for applications in vehicles and confined spaces.
Implementation Method 1
is hollow and encloses a material for storing thermal energy by accumulation of latent heat (such as PCM)
Implementation Method 2
a material for storing thermal energy by accumulation of latent heat (such as PCM)
Implementation Method 3
at least one thermally conductive wall that: at least locally limits said at least one first free space, so that a heat exchange can occur between said first fluid
Data Source
AI summary
The invention relates to a heat exchanger comprising a first free space (7) for a first fluid (3), a thermally conductive wall (11) which, at least locally, delimits said first free space (7), in such a way that an exchange of heat can occur between the first fluid and the thermally conductive wall (11) which is hollow and encloses a material (13) for storing thermal energy by accumulation of latent heat, by heat exchange with at least the first fluid. The first free space (7) is divided into at least two separated channels (7a, 7b) in which two streams of the first fluid (3) can circulate at the same time but separately, the thermally conductive wall (11) which encloses the thermal energy storage material (13) being interposed between the two channels (7a, 7b).