Solid-gas reaction substance-filled reactor and method for manufacturing the same
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Solution Overview
Problem
Conventional solid-gas reaction substance-filled reactors require a filling operation, leading to increased manufacturing time and cost due to the need for filling metal hydride powder into narrow gas flow paths, which complicates the manufacturing process and decreases heat exchange efficiency.
Innovation Solution
A reactor design where solid-gas reaction substances are pre-filled in metallic foil bags and inserted into the reactor's heat medium heat-transfer tubes and spacers, allowing for brazing between these components in a single step, eliminating the need for a separate filling process and reducing manufacturing time and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If metal hydride powder is filled into narrow hydrogen gas flow paths in conventional reactors, then the reactor can store and supply hydrogen, but the filling operation takes a lot of time and increases manufacturing cost
Solution Approach 1:
The reactor is divided into multiple stacked layers, each containing a hydrogen storage unit with metal hydride powder pre-filled in a porous container. This segmentation allows parallel processing and eliminates the need for time-consuming filling operations into narrow flow paths, as each unit is independently prepared and then assembled.
Solution Approach 2:
The metal hydride powder is pre-filled into porous containers before assembly into the reactor structure. This preliminary action is performed when the container is accessible and easy to fill, rather than attempting to fill powder into narrow flow paths after the reactor structure is complete, thereby significantly reducing manufacturing time.
2Quantity of substance
If metal hydride powder is filled into narrow hydrogen gas flow paths, then hydrogen storage is enabled, but the manufacturing process becomes complicated
Solution Approach 1:
The reactor is segmented into modular layers with standardized hydrogen storage units. Each unit consists of a porous container pre-filled with metal hydride powder, which is then assembled into the stacked structure. This modular approach simplifies the manufacturing process by breaking down complex assembly into repetitive, standardized steps.
Solution Approach 2:
The porous container serves multiple functions: it holds the metal hydride powder, provides structural support, and acts as part of the heat exchange system. This multi-functionality reduces the number of separate components needed, thereby simplifying the overall manufacturing process.
3Quantity of substance
If conventional filling operations are used, then the reactor can be manufactured, but manufacturing cost increases
Solution Approach 1:
The metal hydride powder is pre-filled into porous containers in a separate, optimized process before assembly. This allows the filling operation to be performed under optimal conditions rather than attempting to fill powder into narrow, hard-to-access flow paths, thereby reducing labor time and manufacturing cost.
Solution Approach 2:
The reactor is divided into standardized modular units that can be manufactured independently and then assembled. This segmentation allows for economies of scale in manufacturing each module, reducing overall production costs compared to manufacturing the complete reactor as a single complex structure.
4Quantity of substance
If high dimension accuracy is provided for the container, then filling volume of metal hydride is ensured, but manufacturing complexity increases
Solution Approach 1:
The invention changes the physical state and properties of the container by using a porous material with controlled porosity (30-70%). This parameter change allows the container to accommodate metal hydride powder while maintaining structural integrity and heat exchange efficiency, eliminating the need for high dimension accuracy in traditional solid containers.
Solution Approach 2:
A porous container is used instead of a solid-walled container. The porous structure provides void spaces that accommodate the metal hydride powder while maintaining the container's shape and structural strength. This eliminates the need for high manufacturing precision, as the porous structure naturally accommodates volume variations of the powder.
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 reactor achieves efficient heat transfer and eliminates the need for a separate filling operation, shortening the manufacturing period and reducing costs while maintaining heat exchange efficiency.
Implementation Method 1
first to (n+1)-th heat medium heat-transfer tubes (n≥1) with heat medium flow paths for flowing a heat medium
Implementation Method 2
solid substances that are capable of reversibly absorbing and desorbing specific gases such as H2, CO2, and ammonia
Implementation Method 3
reversibly absorbing and desorbing specific gases
Implementation Method 4
These solid-gas reaction substances release heat at the time of absorption
Implementation Method 5
absorbs heat at the time of desorption
Implementation Method 6
Brazing is applied at least between the k-th filled body (1≤k≤n) and the k-th heat medium heat-transfer tube and between the k-th filled body and the (k+1)-th heat medium heat-transfer tube
Data Source
AI summary
A solid-gas reaction substance-filled reactor includes a core part in which heat medium heat-transfer tubes and spacers are alternately stacked, a gas introduction/discharge part that communicates with opening ends of the spacers, and a heat medium introduction/discharge part that communicates with heat medium flow paths. Filled bodies including metallic foil bags and a solid-gas reaction substance filled in the bags are inserted into the spacers. At least the filled bodies and the heat medium heat-transfer tubes are brazed to each other. The solid-gas reaction substance-filled reactor is obtained by stacking the filled bodies with the solid-gas reaction substance filled into the metallic bags, the heat medium heat-transfer tubes, and the spacers in a predetermined order and then brazing them.