High-Efficiency and Low-Cost Polymer WHR Units

C58-12c-280024-Abstract Current state-of-the art heat exchangers typically use copper-tube, aluminum-fin construction, with internal enhancement in the tubes and lances or louvers in the fins to promote heat transfer. However, non-metallic heat exchangers show distinct advantages due to their light weight, manufacturing potential, wide range of geometric design possibilities, corrosion resistance, and potential to be low cost. However, there are some challenges on the use of polymer composites to make efficient heat exchangers: a) low thermal conductivity, b) failure at high operating pressure, c) high porosity in 3D printing. proposes a novel multi-material polymer 3D printing technology to make high efficiency heat exchanger by using polymer/diamond composites to assemble WHR units. Various mixing ratios will be investigated to get optimal performance in mechanical strength, density, and thermal conductivity. TPMS structured heat exchange will be investigated to obtain highest efficiency and verified in experiment. Optimization of heat transfer efficiency will be done in terms of lattice structure, wall thickness, composition ratio, polymer selection. The proposed MMC AM technology is not just limited to the heat exchangers. It can be immediately applied to make products for automobiles, medical instrumentation, and aerospace and defense and to bring the relevant market size over $100B. 1) The MMC material market was estimated to be $787 million in 2027 by a survey from Grand View Research and Mordar Intelligence Analysis. It is expected to register a CAGR of more than 11% during the forecast period. North America accounted for the highest market share. 2) The global automotive brake market was valued at $45.6 billion in 2021. It is expected, from Grand View Research and Straits Research, to reach around $72.7 billion, growing at a CAGR of 5.3% during the forecast period (2022ľ2030). 3) Analysis from Grand View Research and GMI Research finds that the Medical Imaging Market earned revenues of $28.0 billion currently and forecast to touch $47.4 billion in 2030. It will grow at a CAGR of 4.9% from 2022-2030. Summary for Members of Congress. A polymer/diamond composition and 3D printing technique will be developed for heat exchangers. It will enable a new and cost-effective process for Industrial Efficiency and Decarbonization.