Thermal Exchange Channel Geometry Using Unit Cell Optimization
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Solution Overview
Problem
Current methods for designing thermal energy transfer devices are computationally intensive, time-consuming, and struggle with modeling fluid flow and heat transfer, manufacturability, and integration into larger systems, leading to suboptimal performance and inefficiencies.
Innovation Solution
A computer-implemented method optimizing geometric configurations of thermal energy transfer channels by defining a unit cell, iteratively modifying its solid structures until performance criteria are met, using periodic flow and heat transfer equations, and integrating with production equipment to streamline design and manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional methods optimize the entire device configuration, then comprehensive thermal performance is improved, but computational time and resources increase excessively
Solution Approach 1:
The device is divided into multiple unit cells, each representing a discrete thermal management module. By optimizing each unit cell independently and then assembling them, the computational problem is segmented from a single large-scale optimization into multiple smaller, manageable optimizations, significantly reducing computational time while maintaining overall device performance.
Solution Approach 2:
The optimization approach transitions from optimizing the entire 3D device geometry to optimizing 2D unit cell cross-sections that are then extruded or replicated. This dimensional reduction allows for faster computation while preserving the essential thermal characteristics of the full device through periodic boundary conditions and thermal network models.
2Reliability
If complex geometries are designed for optimized thermal performance, then heat transfer efficiency is improved, but manufacturability decreases
Solution Approach 1:
The complex thermal management device is segmented into standardized unit cells with simplified geometries that are easier to manufacture. Each unit cell contains the essential thermal management features but in a modular, manufacturable form that can be produced using conventional manufacturing processes, then assembled into the complete device.
Solution Approach 2:
The design optimizes thermal performance by adjusting parameters within standardized geometric constraints rather than creating entirely complex geometries. Parameters such as fin height, channel width, and rib thickness are optimized within manufacturable ranges, achieving high thermal efficiency while maintaining ease of manufacture through parameter tuning rather than geometric complexity.
3Manufacturing precision
If iterative shape optimization is performed, then geometric precision is improved, but computational resources increase
Solution Approach 1:
Shape optimization is applied to each unit cell independently rather than to the entire device. This segmentation allows iterative optimization algorithms to converge faster on each small unit cell while using thermal network models to evaluate the overall device performance, reducing the computational resources required for each optimization iteration.
Solution Approach 2:
The evaluation of thermal performance during optimization replaces full computational fluid dynamics (CFD) simulations with simplified thermal network models. This substitution maintains geometric precision through iterative optimization while dramatically reducing computational resources by using equivalent thermal circuit models instead of detailed fluid-thermal coupling simulations.
4Productivity
If unit cell level optimization is performed, then computational efficiency is improved, but modeling fluid flow and heat transfer becomes more challenging
Solution Approach 1:
Thermal network models serve as intermediaries between the unit cell geometric optimization and the overall device thermal performance evaluation. These simplified models act as mediators that allow fast evaluation of thermal characteristics during optimization while maintaining accuracy through proper formulation of thermal resistances and capacitances, bridging the gap between simple unit cell models and complex full-device behavior.
Solution Approach 2:
The modeling approach changes from solving full Navier-Stokes and energy equations in each unit cell to using parameter-based thermal network models. By transforming the partial differential equations into algebraic equations representing thermal circuits, the computational efficiency improves while the modeling complexity is managed through systematic parameter extraction and equivalent circuit formulation.
Data Source
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AI summary
The present invention relates to a computer-implemented method and system for optimizing geometric configurations within thermal energy transfer device comprising at least one thermal energy exchange channel to enhance performance. The method involves obtaining target design criteria for a physical object and defining a unit cell dimensioned such that the thermal energy transfer channel is formed by a matrix of N1 × N2 identical unit cells. Shape optimization is performed at the unit cell level by iteratively modifying the boundary surfaces of solid structures within a unit cell based on criteria including performance. Optimized design parameters are outputted and transferred to production equipment for creating an optimized thermal energy transfer device. This device comprises a matrix of structures arrayed in at least one dimension, derived from optimized unit cell models.