ADDITIVELY MANUFACTURED THERMAL ENERGY STORAGE UNITS
20220003509 · 2022-01-06
Inventors
- Travis L. Mayberry (McKinney, TX, US)
- Nicholas I. Maniscalco (Plano, TX, US)
- Katherine P. Carpenter (Plano, TX, US)
- Michael J. Arthur (Indianapolis, IN, US)
Cpc classification
Y02E60/14
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F28D20/028
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F28D20/021
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F28F2255/18
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F28D20/023
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F28F2250/106
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
Abstract
A method of forming a thermal energy storage unit for a surface to be cooled or heated includes using an additive manufacturing process to form a plurality of non-rectilinear structures having a plurality of thermally conductive substructures, the substructures defining a plurality of interior cavities within the substructures and a plurality of exterior fluid channels that cross over or under the plurality of interior cavities, arranging the plurality of non-rectilinear structures in a plurality of housings, wherein each of the plurality of non-rectilinear structures is arranged in a corresponding one of the plurality of housings, and connecting the plurality of housings to each other to build up the thermal energy storage unit whereby the thermal energy storage unit is modular.
Claims
1. A method of forming a thermal energy storage unit for a surface to be cooled or heated, the method comprising: forming a plurality of cores formed of non-rectilinear structures having a plurality of thermally conductive substructures using an additive manufacturing process, the substructures defining a plurality of interior cavities within the substructures and a plurality of exterior fluid channels that cross over or under the plurality of interior cavities; inserting the plurality of cores in a plurality of housings, wherein each of the plurality of cores is arranged in a corresponding one of the plurality of housings; and connecting the plurality of housings to each other to build up the thermal energy storage unit as a modular unit.
2. The method according to claim 1 further comprising forming each of the plurality of housings to have at least one curved surface using an additive manufacturing process, wherein the at least one curved surface is conformal to the surface to be cooled or heated.
3. The method according to claim 2 further comprising forming a corresponding one of the plurality of cores to have a shape that is conformal to a shape of the corresponding one of the plurality of housings.
4. The method according to claim 2 further comprising forming the at least one curved surface to be conformal to the surface to be cooled or heated in an airborne vehicle that is subject to gravity, wherein the plurality of non-rectilinear structures are shaped to be gravity independent and gravitationally agnostic.
5. The method according to claim 2 further comprising forming the at least one curved surface to have a convex curvature that extends between parallel sides of the corresponding one of the plurality of housings.
6. The method according to claim 1, wherein connecting the plurality of housings includes engaging the plurality of housings in a direction of fluid flow through the thermal energy storage unit, wherein the plurality of housings are arranged one-by-one in the direction of fluid flow.
7. The method according to claim 1, wherein connecting the plurality of housings to each other includes engaging interfaces of the plurality of housings that are adjacent to each other.
8. The method according to claim 6 further comprising forming each of the interfaces to extend around an outer periphery of the corresponding one of the plurality of housings.
9. The method according to claim 8 further comprising forming each of the interfaces to extend around a corresponding one of the plurality of non-rectilinear structures arranged in the corresponding one of the plurality of housings whereby the corresponding one of the plurality of cores is exposed to outside the corresponding one of the plurality of housings.
10. The method according to claim 7, wherein engaging the interfaces includes forming a sealed engagement between the interfaces.
11. The method according to claim 7 further comprising: forming each of the plurality of housings to have two interfaces arranged on opposing sides and forming; and forming the two interfaces to be complementary in shape.
12. The method according to claim 1 further comprising: forming two end sections that each have a fluid inlet and a fluid outlet; and connecting the plurality of housings between the two end sections.
13. The method according to claim 1 further comprising: forming each of the plurality of housings to have a top surface, a bottom surface, and opposite sidewalls that extend between the bottom surface and the top surface, each of the plurality of housings defining a flow path that runs parallel with the opposite sidewalls; and arranging a corresponding one of the plurality of non-rectilinear structures to extend from the bottom surface to the top surface.
14. The method according to claim 13 further comprising forming each of the plurality of housings to have curved and non-planar edges that transition between the top surface and the opposite sidewalls, and between the opposite sidewalls and the bottom surface.
15. The method according to claim 13 further comprising forming each of the plurality of housings to have opposite open sides that expose a corresponding one of the plurality of cores to outside a corresponding one of the plurality of housing, the opposite open sides extending between the opposite sidewalls and between the top surface and the bottom surface.
16. The method according to claim 13 further comprising: forming two end sections that each have a fluid inlet and a fluid outlet; connecting a first one of the plurality of housings to a first one of the two end sections, wherein one of the fluid inlet and the fluid outlet of the first one of the two end sections is arranged proximate the top surface of the first one of the plurality of housings and an opposite one of the fluid inlet and fluid outlet of the first one of the two end sections is arranged proximate the bottom surface of the first one of the plurality of housings; and connecting a second one of the plurality of housings to a second one of the two end sections, wherein one of the fluid inlet and the fluid outlet of the second one of the two end sections is arranged proximate the top surface of the second one of the plurality of housings and an opposite one of the fluid inlet and fluid outlet of the second one of the two end sections is arranged proximate the bottom surface of the second one of the plurality of housings
17. The method according to claim 1, wherein using the additive manufacturing process to form the plurality of non-rectilinear structures includes using a 3D printer, wherein a build volume of the 3D printer used to form the plurality of non-rectilinear structures is smaller than a total size of the thermal energy storage unit.
18. The method according to claim 1 further comprising forming the plurality of housings to be identical in shape and size.
19. The method according to claim 1 further comprising arranging a phase change material in one of either the plurality of exterior fluid channels or the plurality of interior cavities.
Description
BRIEF DESCRIPTION OF DRAWINGS
[0031] The annexed drawings, which are not necessarily to scale, show various aspects of the invention.
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DETAILED DESCRIPTION
[0042] The principles described herein have particular application in thermal energy storage units or heat exchangers that are suitable for use in various applications. Examples of suitable applications include applications that use electronics requiring cooling. Exemplary applications include directed energy weapons, lasers, rail guns, hypersonic applications, and engines for short life-span components. The thermal energy storage units may be suitable for use in many other applications, such as applications using high energy duty-cycled electronics or batteries, or applications that require short-term thermal storage without using a heat sink. The thermal energy storage unit is also gravitationally agnostic such that the thermal energy storage unit is suitable for use in environments having different gravitational forces, or zero gravitational forces. Although the thermal energy storage unit is described herein as being particularly applicable for cooling a heat-dissipating surface, such as in an electronic application, the principles described herein may also be suitable for a reverse thermal application in which a cooled surface is to be heated by a heat exchanger.
[0043] Referring first to
[0044] As shown in
[0045] The finstock 16 has a conventional shape that is rectilinear. Due to the rectilinear shape of the finstock 16, when the airborne vehicle containing the thermal energy storage unit 12 is oriented in a horizontal direction, as shown in
[0046] Referring now to
[0047] The compartments are enclosed within the housing 30 and a phase change material (PCM) 32 may be arranged in the housing 30. Any suitable PCM may be used and the PCM is arranged in a thermal conducting thermal energy storage unit that enables the PCM 32 to be cross-flowed with a heat transfer fluid. The housing 30 contains many non-rectilinear areas 32a, 32b in which a thermal energy storage unit and a PCM could be arranged. The cross-flow melts the PCM 32 and heat is transferred from the corresponding components to be cooled, such as the electronics of the airborne vehicle 24. A suitable PCM has a high heat of fusion per unit weight, a large melting point selection, and a low thermal conductivity. Other preferable characteristics of the PCM include non-corrosivity, chemical inertness, and thermal cycle consistency. For example, a suitable PCM is in the form of a paraffin wax which is melted during the phase change of the material. The PCM may also be in the form of a fatty acid, water and/or ice, and hydrated salt.
[0048] Referring now to
[0049] The outer housing 36 of the thermal energy storage unit 34 contains at least one non-rectilinear structure 42 that is arranged in the at least one flow path 40 and formed by a suitable AM process. The non-rectilinear structure 42 is configured to contain the PCM in both solid and liquid form as will be further described below. The non-rectilinear structure 42 may be arranged to accommodate the entire volume of the at least one flow path 40 such that the non-rectilinear structure 42 extends vertically from a first plate 44 to a second plate 46. In contrast to the conventional finstock shown in
[0050] The non-rectilinear structure 42 maximizes the wetted surface area for the PCM and is gravitationally independent by limiting the impact of the dead-volume gap required for expansion of the PCM. Another advantage of the non-rectilinear structure 42 is that the non-rectilinear structure 42 is configured to be gravitationally agnostic, such that a gravity vector acting on the non-rectilinear structure 42 could be in any direction, or not present at all. For example, the non-rectilinear structure 42 is suitable for use in an application in which low or zero gravity exists, such as in an aerospace application in which space or a special terrestrial flight trajectory negates the gravity vector.
[0051] The non-rectilinear structure 42 is shellular in shape and has an outer shell or exterior surface 48 that defines at least one thermally conductive substructure 50. The non-rectilinear structure 42 is formed of a plurality of substructures. The shellular shape may pertain to the non-rectilinear structure 42 having a single, continuous, smooth, interfacial shell that separates two sub-volumes that are intertwined with each other. Accordingly, each substructure 50 is hollow inside and defines an interior cavity that is a first sub-volume. In an exemplary embodiment, each substructure 50 may be interconnected with other hollow substructures to define a truss-like, lattice-type, or tubular cross structure, as shown in
[0052] Each substructure 50 may be formed to have an identical shape and the substructures may be formed in an ordered arrangement as shown in
[0053] In the exemplary embodiment shown in
[0054] The non-rectilinear structure 42 described herein is merely exemplary and the non-rectilinear structure 42 and the corresponding thermally conductive substructures may have any suitable geometric shapes and the shapes may be dependent on the application. For example, the shape of the non-rectilinear structure 42 may be determined using topology optimization in which a suitable software program and processor are used to determine and calculate an optimal geometry for the non-rectilinear structure 42 and the corresponding substructures based on a particular application. The optimal geometry may be determined by determining the boundaries of the application. For example, the boundaries of the housing 16 for the airborne vehicle 10 (shown in
[0055] Other geometries that may be suitable for the non-rectilinear structure 42 include other non-polygonal shapes such as circular shellular shapes, airfoil shellular shapes, pin-shaped fins, elliptical fins, helical shapes, and honeycomb tube shapes. In particular applications, the spacing between each substructure 50 may increase or decrease such that the density decreases or increases. The volume fraction of each substructure 50 may also decrease or decrease along a length of the non-rectilinear structure 42. In still another example, the non-rectilinear structure 42 may be shaped to have triangular branches that progressively increase in size from a central spine of the structure 42, such that the structure 42 has a single substructure 50 at one end and incrementally increases to have a plurality of substructures toward the opposite end. Each substructure 50 may have a different shape. Any structure that maximizes the surface area contact between the thermally conducting substructure 50 and the PCM contained within the non-rectilinear structure 42 may be used. Moreover, the non-rectilinear structure 42 may be sized up or down depending on the application.
[0056] The external fluid channels cross over and under the interior cavities such that the PCM is cross-flowed with a heat transfer fluid. The exterior fluid channels and the interior cavities may be weaved with each other to form a three-dimensional crisscross type pattern. In an exemplary embodiment, the PCM, which may be in the form of a paraffin wax, is arranged in the interior cavities such that the heat transfer fluid flows through each exterior fluid channel 58 across the PCM to melt the PCM. In another exemplary embodiment, the heat transfer fluid may flow through the interior cavities defined by the non-rectilinear structure 42 and the PCM may be arranged outside the interior cavities, but still cross-flowed with the heat transfer fluid. The non-rectilinear structure 42 having airfoil shellular shapes may be particular advantageous for an embodiment in which the PCM is arranged outside the flow paths in that the airfoil structure is shaped in the direction of the fluid flow to lower a pressure drop across the non-rectilinear structure 42 and across the corresponding flow path 40. When the PCM is arranged in either the external fluid channels or the interior cavities, the corresponding medium is provided with the required dead-volume gap for expansion of the PCM during the phase change.
[0057] Using AM to form the non-rectilinear structure 42 and substructures is advantageous in that AM enables complex and non-traditional thermally conductive structures to be formed for a thermal energy storage unit. Any suitable material for AM may be used to form the non-rectilinear structure 42 and substructures. Examples of suitable materials include metal materials such as aluminum and titanium. Other suitable materials include zinconel and nickel superalloys. Many other materials may be suitable and the selection of materials is dependent on the application. Any suitable AM manufacturing process may also be used and examples of suitable processes include 3D printing and metal laser powder bed AM.
[0058] With reference to
[0059] Using AM to form a thermal energy storage unit is further advantageous in forming a modular, large-scale thermal energy storage unit 82 as shown in
[0060] Forming the large-scale thermal energy storage unit 82 is advantageous in that the total size of the unit may be larger than a build volume of an individual 3D printer used to form the core 86 of each section 84. Moreover, forming the large-scale thermal energy storage unit 82 to have modular sections reduces the risk of the entire unit failing due to the failure of only one section 84. The large-scale thermal energy storage 82 may have end sections 90, 92 and any suitable number of sections interposed between the end sections 90, 92. As shown in
[0061] Referring now to
[0062] Step 104 of the method 98 includes providing the PCM in one of either the plurality of exterior fluid channels or the plurality of interior cavities of the non-rectilinear structure 42. Step 106 includes cross-flowing the PCM with a heat transfer fluid. Step 104 may include arranging the PCM in the plurality of interior cavities and step 106 may include cross-flowing the PCM with the heat transfer fluid through the external fluid channels. Step 108 includes building the large-scale, modular thermal energy storage unit 82 (as shown in
[0063] Although the invention has been shown and described with respect to a certain preferred embodiment or embodiments, it is obvious that equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In particular regard to the various functions performed by the above described elements (components, assemblies, devices, compositions, etc.), the terms (including a reference to a “means”) used to describe such elements are intended to correspond, unless otherwise indicated, to any element which performs the specified function of the described element (i.e., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated exemplary embodiment or embodiments of the invention. In addition, while a particular feature of the invention may have been described above with respect to only one or more of several illustrated embodiments, such feature may be combined with one or more other features of the other embodiments, as may be desired and advantageous for any given or particular application.