Pressed SiC Fluid Modules With Integrated Heat Exchange Channels
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Solution Overview
Problem
The economical production of flow reactors with long residence time and high heat exchange performance using ceramics like silicon carbide is challenging due to their high hardness and abrasiveness, which complicates the integration of efficient heat exchange systems.
Innovation Solution
The fabrication of pressed ceramic fluid modules with surface heat exchange channel layers, where heat exchange channels are embedded during the pressing process, allowing for stacked modules with integrated heat exchange channels that eliminate the need for external metallic heat exchange plates and reduce hardware requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If external metallic heat exchange plates are used, then heat exchange performance is improved, but device complexity and cost increase
Solution Approach 1:
The patent merges the heat exchange function with the fluid module structure by embedding heat exchange channels directly into the ceramic body during the pressing process. This integration eliminates the need for separate external metallic heat exchange plates and their associated interconnection hardware, thereby reducing device complexity while maintaining heat exchange performance.
Solution Approach 2:
The ceramic fluid module is designed to perform multiple functions simultaneously: it serves as both the fluid containment structure and the heat exchange medium. The heat exchange channels are formed as integral parts of the ceramic module, allowing the same component to handle both fluid flow and thermal transfer operations.
2Temperature
If external heat exchange plates are used, then heat exchange performance is improved, but reactor system volume increases
Solution Approach 1:
By combining the heat exchange channels with the fluid module structure, the patent eliminates the need for separate external heat exchange plates and interconnection hardware. This integration significantly reduces the overall reactor system volume while maintaining effective heat exchange performance.
3Strength
If traditional ceramic processing is used, then material properties are maintained, but manufacturing difficulty increases due to high hardness and abrasiveness
Solution Approach 1:
The patent performs the heat exchange channel formation during the initial pressing process, before the ceramic material undergoes sintering and hardening. By creating the channels in the green state (unsintered) ceramic using a mold, the manufacturing process avoids the difficulty of machining hard, sintered ceramic, while still achieving the desired structural integrity and material properties.
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 approach reduces reactor system costs and volume by integrating heat exchange channels within the modules, enhancing heat transfer performance and allowing for more compact reactor designs without additional fabrication complexity.
Implementation Method 1
During pressing the SiC powder and the wax forms compress and maintain their relative positions, and after sintering, an internal reactant channel path and a channel in the surface of the pressed fluidic module are formed
Implementation Method 2
The heat exchange channel can accept a piece of heat exchange tubing, which can be pressed into the channel and retained in place
Data Source
AI summary
A flow reactor or flow reactor component includes a base plate, a first fluid module having first and second major surfaces, an internal process fluid passage, and a heat exchange channel in the first major surface, the first major surface stacked on the base plate; a second fluid module having first and second major surfaces, an internal process fluid passage and a heat exchange channel in the first major surface, the first major surface stacked on the second major surface of the first fluid module, optional additional fluid modules of the same configuration as the first and second fluid modules stacked successively on the second fluid module, and a top plate having a heat exchange channel in a bottom major surface thereof with the bottom major surface stacked on an uppermost fluid module of (1) the second fluid module and (2) the optional additional fluid modules.