3D-Printed Zeolite Structure With Embedded Wire for Uniform Desorption Heating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing zeolite systems for adsorption in space or deep-water exploration face challenges in minimizing size, reducing power consumption during desorption, and ensuring uniform heating due to poor thermal conductivity and hot spots from external heating elements.
Innovation Solution
A process for fabricating a zeolite structure with an embedded high-resistivity wire for Joule heating, using additive manufacturing to embed the wire within the structure, allowing for uniform heating and mechanical reinforcement while reducing system size and power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If external heating elements are used for desorption, then heating capability is achieved, but hot spots are created due to poor thermal conductivity
Solution Approach 1:
The heating element (wire) is merged with the zeolite structure by embedding it directly into the adsorbent material during additive manufacturing. This integration ensures direct thermal coupling throughout the zeolite bed, eliminating thermal resistance interfaces and preventing hot spots while achieving uniform heating during desorption.
Solution Approach 2:
The patent replaces traditional thermal conduction-based heating (which creates hot spots due to poor thermal conductivity) with Joule heating through embedded resistive wires. This substitution uses electrical resistance heating directly within the zeolite structure, providing uniform heat generation throughout the volume rather than heat transfer from external surfaces.
2Temperature
If heating blankets or external heating elements are used, then desorption heating is achieved, but system size increases
Solution Approach 1:
The heating wire is nested within the zeolite structure during additive manufacturing, with the wire being embedded inside the adsorbent material. This nesting approach integrates the heating function within the existing structure volume, eliminating the need for external heating blankets or separate heating components that would increase overall system size.
Solution Approach 2:
The heating function is merged with the zeolite structure itself by embedding conductive wires within the adsorbent material. This combination eliminates separate heating components and reduces system size, as the structure serves dual purposes: adsorption and self-heating.
3Temperature
If external heating elements are used, then heating function is provided, but temperature ramp-up time increases
Solution Approach 1:
The patent replaces slow thermal conduction heating from external sources with rapid Joule heating generated directly within embedded wires. This substitution enables fast temperature ramp-up by generating heat internally throughout the zeolite structure, eliminating the time delay associated with heat transfer through thermal conduction.
Solution Approach 2:
The zeolite structure with embedded wires performs self-heating through Joule effect when electrical current is applied. This self-service capability eliminates the need for external heating systems and enables rapid temperature increase, as the heat is generated directly within the structure rather than being transferred from outside.
4Temperature
If traditional heating methods are used, then heating is achieved, but mechanical reinforcement is insufficient
Solution Approach 1:
The embedded wire serves multiple functions simultaneously: it provides Joule heating for desorption, acts as a mechanical reinforcement element within the additive manufactured structure, and serves as a structural component of the zeolite bed. This multi-functionality addresses both heating requirements and mechanical strength needs with a single integrated solution.
Solution Approach 2:
The heating element and structural reinforcement are merged into a single component (the embedded wire). This wire simultaneously provides thermal function through Joule heating and mechanical function through structural reinforcement, eliminating the need for separate heating elements that would add weight and complexity.
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 embedded wire enables uniform heating, reduces system size, and decreases power consumption and temperature ramp-up time, enhancing mechanical properties and thermal efficiency.
Implementation Method 1
By embedding a wire into the zeolite bed/structure, specifically a wire with a high (>1 Ω/ft) resistivity (e.g., Nickel-chromium), the zeolite can be heated for desorption by Joule heating with the embedded wire; resulting in uniform heating of all sections of the structure.
Data Source
AI summary
A process for fabricating a structure of a zeolite-based paste with an intra-layer continuous wire embedded is disclosed. The structure is made of multiple layers stacked together, produced by an additive manufacturing (3D printing) process. Within this structure, at least one wire is embedded through a section of a layer or a layer in its entirety, where the wire comprises of both the encapsulated section within the structure and two bare wire leads protruding from the structure. The flowcharts for the overall process of the structure fabrication, as well as a flowchart for the specific process of fabricating the wire embedded layers is disclosed. The primary goal of this process is to fabricate a zeolite structure with an embedded, high resistance wire for uniform Joule heating for reduced power consumption and temperature ramp-up time during a desorption process.