METHOD OF ASSEMBLING AN ELECTROCALORIC ARTICLE AND ELECTROCALORIC HEAT TRANSFER SYSTEM
20210308733 · 2021-10-07
Inventors
- Subramanyaravi Annapragada (South Windsor, CT, US)
- Scott Alan Eastman (Glastonbury, CT, US)
- Joseph V. Mantese (Ellington, CT, US)
- Wei Xie (Malden, MA, US)
- Wayde R. Schmidt (Pomfret Center, CT)
- Craig R. Walker (South Glastonbury, CT, US)
- Sameh Dardona (South Windsor, CT)
- Slade R. Culp (Coventry, CT, US)
Cpc classification
F25B21/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02B30/00
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
F25B2321/001
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B21D5/01
PERFORMING OPERATIONS; TRANSPORTING
International classification
B21D5/01
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A method of making an electrocaloric article is disclosed in which a continuous sheet of an electrocaloric film is bent back and forth to form a plurality of connected aligned segments of electrocaloric film with gaps between film surfaces of adjacent aligned segments. The continuous sheet of electrocaloric film is secured in this with a securing method that includes attaching a spacer to the continuous sheet of electrocaloric film prior to the back and forth bending; or providing a spacer comprising a base and a plurality of projections extending from the base, and inserting the projections into the gaps between the film surfaces of adjacent aligned segments after the back and forth bending; or interweaving a continuous spacer through the gaps between the aligned segments of the electrocaloric film; or attaching an end cap to a plurality of connecting portions of the electrocaloric film between the aligned segments.
Claims
1. A method of making an electrocaloric article, comprising: bending a continuous sheet of an electrocaloric film back and forth to form a plurality of connected aligned segments of electrocaloric film in a configuration that includes gaps between film surfaces of adjacent aligned segments; and securing the continuous sheet of electrocaloric film in said configuration of connected aligned segments including gaps between film surfaces of adjacent aligned segments with a securing method that includes: attaching a spacer to the continuous sheet of electrocaloric film prior to the back and forth bending; or providing a spacer comprising a base and a plurality of projections extending from the base, and inserting the projections into the gaps between the film surfaces of adjacent aligned segments after the back and forth bending; or interweaving a continuous spacer through said gaps between the aligned segments of the electrocaloric film; or attaching an end cap to a plurality of connecting portions of the electrocaloric film between the aligned segments.
2. The method of claim 1, wherein the securing method includes attaching the spacer to the continuous sheet of electrocaloric film prior to the back and forth bending.
3. The method of claim 2, wherein the securing method includes dispensing the continuous sheet of electrocaloric film from a roll of electrocaloric film and attaching the spacer to the dispensed electrocaloric film prior to the back and forth bending.
4. (canceled)
5. The method of claim 2, wherein the securing method includes attaching the plurality of spacers to the continuous sheet of electrocaloric film prior to the back and forth bending.
6. The method of claim 1, wherein the securing method includes providing a spacer comprising a base and a plurality of projections extending from the base and inserting the projections into the gaps between the film surfaces of adjacent aligned segments after the back and forth bending.
7. (canceled)
8. The method of claim 6, the securing method includes inserting the projections of a first spacer into the gaps at a first location between the film surfaces at a first edge of a plurality of adjacent aligned segments, inserting the projections of a second spacer into the gaps at a second location between the film surfaces at a second edge of a plurality of adjacent aligned segments opposite the first edge, and engaging the projections of the first and second spacer structures.
9. The method of claim 1, wherein the securing method includes interweaving a continuous spacer through said gaps between the aligned segments of the electrocaloric film.
10. (canceled)
11. The method of claim 1, wherein the securing method includes attaching an end cap to a plurality of connecting portions of the electrocaloric film between the aligned segments.
12. The method of claim 11, wherein the end cap is electrically conductive and is electrically connected to an electrode on the electrocaloric film.
13. The method of claim 11, wherein attaching the end cap to the plurality of connecting portions of the electrocaloric film includes fusing, potting, or molding the end cap to the electrocaloric film.
14. The method of claim 1, wherein the spacer is electrically non-conductive.
15. The method of claim 1, wherein the spacer is electrically conductive.
16. The method of claim 1, further comprising connecting an electrode or electrodes on the electrocaloric film to a power control circuit.
17. The method of claim 16, wherein the spacer is electrically conductive and is electrically connected to the electrode and the power control circuit.
18. The method of claim 16, wherein the electrode or the electrically-conductive spacer is electrically connected to the power control circuit through an electrical bus.
19. The method of claim 1, wherein the bending of the continuous sheet of electrocaloric film imparts the configuration of connected aligned segments with alternating large and small gaps.
20. The method of claim 19, further comprising disposing a support in said small gaps.
21. The method of claim 1, wherein bending the continuous sheet of electrocaloric film includes engaging the electrocaloric film with a supporting structure to position or maintain the electrocaloric film in the configuration comprising aligned segments, and wherein the electrocaloric film is disengaged from the supporting structure after performing the securing method.
22. The method of claim 1, further comprising pre-folding the electrocaloric film prior to bending back and forth to form the plurality of connected aligned segments.
23. A heat transfer system, comprising a plurality of supported electrocaloric film segments arranged and secured in a stack, prepared according to the method of claim 1; a working fluid flow path through the stack, said working fluid flow path disposed in gaps between adjacent aligned electrocaloric film segments, said working fluid flow path in operative thermal communication with a heat sink and a heat source at opposite ends of the working fluid flow path; a plurality of electrodes arranged to generate an electric field in the electrocaloric film segments and connected to a power source configured to selectively apply voltage to activate the electrodes in coordination with fluid flow along the working fluid flow path to transfer heat from the heat source to the heat sink.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:
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DETAILED DESCRIPTION
[0037] A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.
[0038] As mentioned above, electrocaloric articles are disclosed that include adjacent aligned segments of a continuous sheet of electrocaloric film. An example embodiment of such an article 10 with segments in a stack-like configuration is schematically shown in
[0039] Liquid crystal polymers, or polymer liquid crystals comprise polymer molecules that include mesogenic groups. Mesogenic molecular structures are well-known and are often described as rod-like or disk-like molecular structures having electron density orientations that produce a dipole moment in response to an external field such as an external electric field. Liquid crystal polymers typically comprise numerous mesogenic groups connected by non-mesogenic molecular structures. The non-mesogenic connecting structures and their connection, placement and spacing in the polymer molecule along with mesogenic structures are important in providing the fluid deformable response to the external field. Typically, the connecting structures provide stiffness low enough so that molecular realignment is induced by application of the external field, and high enough to provide the characteristics of a polymer when the external field is not applied. In some exemplary embodiments, a liquid crystal polymer can have rod-like mesogenic structures in the polymer backbone separated by non-mesogenic spacer groups having flexibility to allow for re-ordering of the mesogenic groups in response to an external field. Such polymers are also known as main-chain liquid crystal polymers. In some exemplary embodiments, a liquid crystal polymer can have rod-like mesogenic structures attached as side groups attached to the polymer backbone. Such polymers are also known as side-chain liquid crystal polymers.
[0040] The electrodes 16 and 18 on the electrocaloric film can take different forms with various electrically conductive components. The electrodes can be any type of conductive material, including but not limited to metallized layers of a conductive metal such as aluminum or copper, or other conductive materials such as carbon (e.g., carbon nanotubes, graphene, or other conductive carbon). Noble metals can also be used but are not required. Other conductive materials such as a doped semiconductor, ceramic, or polymer, or conductive polymers can also be used. In some embodiments, the electrodes can be in the form of metalized layers or patterns on each side of the film such as disclosed in published PCT application WO 2017/111921 A1 or U.S. patent application 62/521,080, the disclosures of each of which is incorporated herein by reference in its entirety.
[0041] With continued reference now to
[0042] As mentioned above, in some embodiments, the electrocaloric film can be secured in a configuration of aligned connected segments by attaching a spacer to a continuous sheet of electrocaloric film prior to bending of the sheet back and forth. An example embodiment of such an attachment technique is schematically shown in
[0043] An example embodiment showing bending of an electrocaloric film 12 with spacers 24 attached thereto (e.g., attached as part of a roll processing operation as shown in the example embodiment of
[0044] The assembly operation shown in
[0045] Example embodiments of engagement of spacers with aligned segments of electrocaloric film are shown in
[0046] The embodiments disclosed above include bending methods in which folding, including asymmetric folding, can produce a stack-like configuration of connected aligned film segments. In other embodiments, the film can be woven or guided into a stack-like configuration as shown in the example embodiment of
[0047] As mentioned above, in some embodiments, a securing method includes attaching an end cap to a plurality of connecting portions of the electrocaloric film between the aligned segments. Such a securing method is schematically shown along with other features in
[0048] The spacers 24, end caps 26/28, or supports 33 can be electrically conductive or electrically non-conductive, depending on system design parameters. As seen in the Figures above, the back and forth bending of the electrocaloric film provides an orientation of the film where the electrodes 16 on the segments 20 face each other across the gaps 22, and the electrodes 14 on the segments 20 face each other across the small gaps into which the supports 33 are inserted in
[0049] Additionally, the end caps 26 and 28 have been described herein in the context of electrically-conductive electrical bus end cap embodiments in which a common electrical connection is provided to the electrocaloric film electrodes 18/16 disposed on the connecting portions 42/44, or to electrically-conductive spacers 24, or both, for connection to a power circuit and/or electrical ground. However, the end caps 26/28 can also be electrically non-conductive, with the electrical connection routed through a separate electrical bus (not shown) or individual electrical connections (not shown) to electrodes on the electrocaloric film segments 20 or to individual spacers 24. Similarly, the planar inserts 33 can also be electrically conductive or electrically non-conductive.
[0050] The spacers 24/36/42/44, end caps 26/28, and supports 33, as well as other components of the electrocaloric article or stack such as housing components, support components, etc., can be made of various materials including but not limited to plastics (e.g., moldable thermoplastics such as polypropylene), ceramics, aerogels, cardboard, fiber composites, or metals. Where electrical conductivity is specified, the component can be made of a conductive material such as metal or an electrically-conductive polymer or composite, or can include a non-conductive substrate such as plastic and an electrically-conductive coating disposed on a surface of the non-conductive substrate. Similarly, where an electrical non-conductive component is specified, the component can be made of a non-conductive material such as a thermoplastic (e.g., polypropylene) or can include an electrically-conductive substrate such as metal and an electrically-conductive coating disposed on a surface of the substrate.
[0051] An example embodiment of a heat transfer system and its operation are further described with respect to
[0052] In operation, the system 310 can be operated by the controller 324 applying an electric field as a voltage differential across the electrocaloric films in the stack to cause a decrease in entropy and a release of heat energy by the electrocaloric films. The controller 324 opens the control device 326 to transfer at least a portion of the released heat energy along flow path 318 to heat sink 317. This transfer of heat can occur after the temperature of the electrocaloric films has risen to a threshold temperature. In some embodiments, heat transfer to the heat sink 317 is begun as soon as the temperature of the electrocaloric films increases to be about equal to the temperature of the heat sink 317. After application of the electric field for a time to induce a desired release and transfer of heat energy from the electrocaloric films to the heat sink 317, the electric field can be removed. Removal of the electric field causes an increase in entropy and a decrease in heat energy of the electrocaloric films. This decrease in heat energy manifests as a reduction in temperature of the electrocaloric films to a temperature below that of the heat source 320. The controller 324 closes control device 326 to terminate flow along flow path 318 and opens control device 328 to transfer heat energy from the heat source 320 to the colder electrocaloric films in order to regenerate the electrocaloric films for another cycle.
[0053] In some embodiments, for example where a heat transfer system is utilized to maintain a temperature in a conditioned space or thermal target, the electric field can be applied to the electrocaloric films to increase temperature until the temperature reaches a first threshold. After the first temperature threshold, the controller 324 opens control device 326 to transfer heat from the stack to the heat sink 317 until a second temperature threshold is reached. The electric field can continue to be applied during all or a portion of the time period between the first and second temperature thresholds and is then removed to reduce the temperature until a third temperature threshold is reached. The controller 324 then closes control device 326 to terminate heat flow transfer along heat flow path 318 and opens control device 328 to transfer heat from the heat source 320 to the stack. The above steps can be optionally repeated until a target temperature of the conditioned space or thermal target (which can be either the heat source or the heat sink) is reached.
[0054] Although any directions described herein (e.g., “up”, “down”, “top”, “bottom”, “left”, “right”, “over”, “under”, etc.) are considered to be arbitrary and to not have any absolute meaning but only a meaning relative to other directions. For convenience, unless otherwise indicated, the terms shall be relative to the view of the Figure shown on the page, i.e., “up” or “top” refers to the top of the page, “bottom” or “under” refers to the bottom of the page, “right” to the right-hand side of the page, and “left” to the left-hand side of the page.
[0055] The term “about” is intended to include the degree of error associated with measurement of the particular quantity based upon the equipment available at the time of filing the application. For example, “about” can include a range of ±8% or 5%, or 2% of a given value.
[0056] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present disclosure. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, element components, and/or groups thereof.
[0057] While the present disclosure has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the essential scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this present disclosure, but that the present disclosure will include all embodiments falling within the scope of the claims.