Skip to main content
OSTI.GOVU.S. Department of Energy Office of Scientific and Technical Information
U.S. Department of Energy
Office of Scientific and Technical Information
 

Joining Techniques for Novel Metal Polymer Hybrid Heat Exchangers

Conference ·
 [1];  [2];  [2];  [2];  [2];  [2];  [2];  [2];  [2];  [2];  [2];  [2]
  1. Univ. of Illinois, Urbana, IL (United States). Dept. of Mechanical Science and Engineering; Advanced Manufacturing Office
  2. Univ. of Illinois, Urbana, IL (United States). Dept. of Mechanical Science and Engineering
+ Show Author Affiliations

Low-grade heat (<220 °C) comprises between 50 to 60% of the unrecovered energy from industrial processes [1]. Traditional heat exchangers (HX) are typically too expensive for such applications where the payback period is typically less than 3 years [2]. Polymers, though more affordable, are usually unsuitable for HX applications due to their low thermal conductivity (~0.2 W/mK). Here we show that metal-polymer hybrids may be attractive from both performance and cost perspectives. The use of polymers further increases the resistance to fouling by sulfuric and carbonic acids. An ongoing work explores different configurations of layered Kapton-copper composites for HX applications using numerical simulations. This paper explores a manufacturing pathway for producing such layered Kapton-copper composite tubes that involves directly rolling and bonding tapes made of polymer and copper foil into tubes. We propose and develop a prototype computer-controlled tube roll-bonding machine, capable of fabricating composite tubes with diameter 25 mm and lengths of 200 mm. A critical problem in the fabrication process is the bonding of metal and polymers [3]. We explore approaches involving adhesives (epoxy, acrylic, silicone) and as well as direct welding (laser and ultrasonic) that can be integrated into the manufacturing process. We report characterizations of the thermomechanical properties of these joining processes. This work paves the way for realizing cost-effective manufacturing of heat exchangers for low grade waste heat recovery.

Keywords: copper, polymer, Kapton, joining techniques, adhesives, dissimilar materials heat exchangers, roll-to-roll process

References:
[1] "1BCS, Incorporated. Waste Heat Recovery: Technology and Opportunities in U. S. Industry. Prepared for the U.S. Department of Energy, Industrial Technologies Program," 2008.

[2] A. Thekdi and S. U. Nimbalkar, "Industrial Waste Heat Recovery-Potential Applications, Available Technologies and Crosscutting R&D Opportunities. Oak Ridge National Lab," 2015.

[3] B. Escaig., Binding metals to polymers. A short review of basic physical mechanisms., Journal de Physique IV Colloque, 1993, 03 (C7), pp.C7-753-C7-761.

Research Organization:
University of Illinois
Sponsoring Organization:
USDOE Office of Energy Efficiency and Renewable Energy (EERE), Advanced Manufacturing Office (EE-5A)
DOE Contract Number:
EE0008312
OSTI ID:
1500130
Report Number(s):
DOE-UIUC-0008312-7
Country of Publication:
United States
Language:
English

Similar Records

JOINING TECHNIQUES FOR NOVEL METAL POLYMER HYBRID HEAT EXCHANGERS
Conference · Mon Nov 11 23:00:00 EST 2019 · OSTI ID:1576962
Joining Techniques for Novel Metal Polymer Hybrid Heat Exchangers
Conference · Mon Jan 20 23:00:00 EST 2020 · OSTI ID:1798637
JOINING TECHNIQUES FOR NOVEL METAL POLY MER HYBRID HEAT EXCHANGERS
Conference · Mon Nov 11 23:00:00 EST 2019 · OSTI ID:1577136

Related Subjects