Heat Exchanger With Phase Change Material Cells
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Solution Overview
Problem
Current heat exchanger manufacturing techniques fail to produce modules with fluid circuits and phase change material cells that can achieve desired dimensions and shapes for high-volume storage capacity and efficient heat exchange at high temperatures, particularly above 200°C, while maintaining mechanical strength and flexibility in channel geometry.
Innovation Solution
A method involving machining grooves in metal plates, assembling them through diffusion welding or brazing, and filling the cells with phase change materials, allowing for adaptable cell dimensions and shapes, and enabling high porosity and thermal performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional heat exchanger manufacturing techniques are used, then production is simpler, but the desired dimensions and shapes for high-volume storage capacity and efficient heat exchange cannot be achieved
Solution Approach 1:
The heat exchanger is divided into modular plates with grooves that form cells when assembled. Each plate can be independently manufactured with precise groove dimensions, and the modular assembly allows flexibility in configuring cell dimensions and shapes while maintaining manufacturing simplicity through standardized plate production
Solution Approach 2:
The invention enables variation of cell dimensions and shapes by changing the groove geometry parameters during plate manufacturing. By adjusting groove depth, width, and pattern, the design can optimize storage capacity and heat exchange efficiency without requiring entirely different manufacturing processes
2Quantity of substance
If high porosity is achieved for large volume storage capacity, then thermal storage capacity increases, but mechanical strength may be compromised
Solution Approach 1:
The heat exchanger uses composite construction with metal plates providing structural strength and grooves forming voids for phase change material storage. The plate material and groove geometry are optimized to achieve high porosity while maintaining sufficient mechanical strength through the rigid plate structure
Solution Approach 2:
The groove walls act as thin film structures that define the cells while maintaining mechanical integrity. The groove geometry is designed to provide sufficient wall thickness for strength while maximizing the void space for phase change material storage, achieving high porosity without compromising structural strength
3Productivity
If complex geometries are implemented for efficient heat exchange, then thermal performance improves, but manufacturing difficulty increases
Solution Approach 1:
Complex heat exchange geometries are achieved by assembling multiple plates with different groove patterns. Each plate can be manufactured with standardized precision, and the combination of plates creates complex three-dimensional fluid circulation paths and cell arrangements that enhance heat exchange efficiency without requiring complex manufacturing processes
Solution Approach 2:
The invention utilizes the third dimension by creating grooves at various depths and angles in the plates. This allows complex heat exchange geometries to be formed through the thickness of the plates and in the assembled structure, enabling efficient thermal performance while maintaining manufacturability through conventional machining techniques
4Strength
If diffusion welding or brazing is used for assembling plates, then mechanical resistance increases, but manufacturing process complexity increases
Solution Approach 1:
The groove formation and plate assembly processes are combined into an integrated manufacturing approach. The grooves are machined in the plates during standard fabrication, and the plates are assembled using diffusion welding or brazing to create strong joints. This merging of functions achieves high mechanical resistance while keeping the overall process manageable through standard industrial 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
The method enables the production of heat exchangers with high mechanical resistance, large thermal storage capacity, and rapid heating or cooling, suitable for high-temperature applications, while allowing for various geometries and reducing material costs.
Implementation Method 1
phase change materials (PCM) are materials capable of exhibiting a reversible physical phase change, the associated variation of enthalpy (or latent heat) of which allows the storage and release of thermal energy
Implementation Method 2
the associated variation of enthalpy (or latent heat) of which allows the storage and release of thermal energy
Implementation Method 3
assembling them through diffusion welding or brazing
Implementation Method 4
assembling them through diffusion welding or brazing
Data Source
AI summary
The invention relates to a heat-exchanger module (1) comprising at least one fluid circuit comprising at least one fluid-circulation channel (13), at least one cell containing a phase-change material (PCM) such as a metal alloy or salt, at least the cell(s) being defined by walls (10) of at least one first metal plate (10.1, 10.2, 10.3) which can be welded, diffusion welded or brazed onto a second metal plate (10.1, 10.2, 10.3). The invention relates to the related manufacturing methods as well as to the uses at high temperatures.