Unit-Cell Heat Exchanger Geometry for Faster Thermal Optimization
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Solution Overview
Problem
Conventional thermal energy transfer devices face challenges in design and optimization due to computational intensity, inflexibility, scalability issues, and inefficiencies, which hinder their adaptability and responsiveness to market needs.
Innovation Solution
A computer-implemented method optimizes geometric configurations of thermal energy transfer devices by structuring them into a matrix of identical unit cells, performing shape optimization at the unit cell level, and integrating fluid stream optimizations to enhance performance and scalability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If comprehensive thermal dynamics simulations are performed for design optimization, then design performance is improved, but computational resources and time are significantly increased
Solution Approach 1:
The thermal energy transfer device is divided into multiple identical unit cells arranged in a matrix configuration. Each unit cell contains a repeatable pattern of thermal energy transfer channels and solid structures. By performing optimization simulations on a single unit cell rather than the entire device, the computational domain is segmented and reduced, significantly decreasing computational resources and time while maintaining design performance through the periodic repetition of the optimized unit cell pattern throughout the complete device.
2Measurement precision
If devices are designed for specific performance parameters and operating conditions, then optimization precision is improved, but flexibility and scalability are limited
Solution Approach 1:
The device employs a universal unit cell design that can be replicated and scaled to meet different performance requirements and operating conditions. The identical unit cells with periodic patterns allow the same basic design to serve multiple applications by simply changing the number of unit cells in the matrix arrangement, thereby achieving both optimization precision for specific parameters and flexibility for different applications without requiring complete redesigns.
Solution Approach 2:
The matrix arrangement of unit cells allows dynamic scaling of the device configuration. By adjusting the number of unit cells in each dimension (N1, N2, N3), the device can be adapted to different sizes, capacities, and thermal performance requirements while maintaining the optimized geometric configuration within each unit cell, enabling the design to respond dynamically to different market needs and technological advancements.
3Device complexity
If traditional design methods based on heuristic rules are used, then design simplicity is maintained, but design performance and application tuning are insufficient
Solution Approach 1:
Instead of relying on heuristic design rules that may not be optimally tuned, the invention uses computational simulations to determine the optimal geometric configuration for a single unit cell, then copies this optimized pattern throughout the entire device. This approach maintains design simplicity through repetition while achieving superior design performance through scientifically optimized unit cell geometry, eliminating the need for trial-and-error adjustments in each application.
4Adaptability or versatility
If complete redesign is performed to adapt devices to different sizes or capacities, then adaptability is improved, but resource consumption and time are increased
Solution Approach 1:
The device is segmented into modular unit cells that can be independently optimized and then replicated. When adaptation to different sizes or capacities is needed, only the number of unit cells in the matrix arrangement needs to be changed, not the entire design. This segmentation approach enables adaptability while minimizing resource consumption, as the optimized unit cell design is simply copied and scaled rather than completely redesigned.
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 computational complexity, enables rapid design iteration, and facilitates modular, scalable, and efficient thermal energy transfer devices with improved performance characteristics.
Implementation Method 1
a plurality of solid structures are arranged in a periodic configuration (e.g. repetitive arrangement/pattern) for facilitating transfer of thermal energy from one fluid to another
Implementation Method 2
at least a first thermal energy transfer channel and a second thermal energy transfer channel in a vertically stacked arrangement relative to one another
Data Source
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AI summary
A method and system for optimizing the geometric configuration of a thermal energy transfer device featuring vertically stacked thermal energy channels separated by a wall structure. The device is conceptualized as composed of N1 × N2 × N3 identical unit cells, each encompassing parts of the channels. Optimization is conducted at the unit cell level, focusing on the geometry of solid structures within the channels to enhance thermal energy transfer between the involved fluid streams/flows within each of the at least two channels. This is achieved through shape optimization using a processing unit, which iteratively adjusts the boundaries of these structures based on predefined criteria until a specific performance threshold is met or a maximum number of iterations is reached. The outcome is optimized design parameters that define the geometry of the solid structures in each unit cell. These parameters are then utilized to guide the manufacturing of the optimized thermal energy transfer device.