Small-Scale Thermal Energy Harvester With Copper Foams and Thermal Energy Storage

Abstract

This article investigates the use of advanced, high porosity thermally conductive foams and a thermal energy storage (TES) device for small scale thermal energy harvesting. In final application, it may be employed in various real world situations that include existing systems like thermoelectric generators (TEGs) and thermal scavenging systems that provide power output from freely available thermal sources. Experimental tests were conducted using various porosity metallic copper foams ranging from 85 % to 89 % porosity. Copper foams were selected to serve as the heat exchanger innards and examined for several key attributes. These included the ability of the foams to yield capillary action with working fluids like water or 3M™ HFE7200. Thermal energy absorption by the exchanger to the working fluid was also monitored. These results were compared to other exchangers based on capillary channel fabrication techniques as previously reported by the research team. Full characterization was based on operating temperature, measured thermal input, mass transfer rate, and heat transfer capability. Preliminary investigation of a matching, small-scale TES unit designed to integrate with the heat exchanger and a future thermoelectric for energy harvesting application was also conducted. Thermal storage was accomplished via solid-liquid phase change of a paraffin wax within the TES device forming a so-called “thermal battery.” In a final design, the TES includes what is defined by thermodynamics as heat pipes. The integrations of several heat pipes, made of copper tubing and filled with working fluid, mounted vertically and immersed in the wax medium will transfer heat to the wax by means of thermal conductivity and phase transition. This represents a first of its kind in this small-scale, thermal harvesting application. The specific tests performed in this initial work included one TES unit filled with a paraffin wax medium and a second that contained several copper vertically placed tubes surrounded by the paraffin wax. The overall thermal conductivity of the phase change medium (wax) was investigated for both constructions as was the ability of each to absorb thermal energy directly. Results indicated capillary action of the working fluid was possible via incorporation of copper foams within the heat exchanger. Maximum heat flux observed in exchanger tests was 0.27 kW/m2 given an operating temperature of 76.6 °C and 2.5W thermal input. Thermal storage tests indicated a maximum thermal capture rate of 0.91 W and phase change material thermal conductivity of 1.00 W/mK for the TES device constructed with copper tubing innards. This compared favorably to the baseline wax conductivity of approximately 0.32 W/mK. Future efforts will fully incorporate both the heat exchanger and matching TES device for a complete harvesting and thermal capture system. The ability of the exchanger to provide thermal energy for storage to the “thermal battery” will be monitored.