Mixed Carbon Foam/Metallic Heat Exchanger

Abstract

A heat exchanger includes a thermally-conductive fluid barrier having first and second surfaces, at least one first type of foam element placed in thermally-conductive contact with the first surface of the thermally-conductive fluid barrier and having a first coefficient of thermal expansion and at least one second type of foam element placed in thermally-conductive contact with the second surface of the thermally-conductive fluid barrier and having a second coefficient of thermal expansion. The first coefficient of thermal expansion of the first type of foam element and the second coefficient of thermal expansion of the second type of foam element are substantially different.

1 . A heat exchanger, comprising:
 a thermally-conductive fluid barrier having first and second surfaces;   at least one first type of foam element placed in thermally-conductive contact with said first surface of said thermally-conductive fluid barrier and having a first coefficient of thermal expansion;   at least one second type of foam element placed in thermally-conductive contact with said second surface of said thermally-conductive fluid barrier and having a second coefficient of thermal expansion; and   wherein said first coefficient of thermal expansion of said first type of foam element and said second coefficient of thermal expansion of said second type of foam element are substantially different.   
   
   
       2 . The heat exchanger of  claim 1  wherein said first type of foam element comprises a reticulated metal foam layer. 
   
   
       3 . The heat exchanger of  claim 2  wherein said reticulated metal foam layer comprises reticulated aluminum foam. 
   
   
       4 . The heat exchanger of  claim 1  wherein said second type of foam element comprises a thermally conductive carbon foam layer. 
   
   
       5 . The heat exchanger of  claim 4  wherein said thermally conductive carbon foam layer is segmented in multiple sections. 
   
   
       6 . The heat exchanger of  claim 1  further comprising a plurality of stress relief blind slots provided in said first type of foam element. 
   
   
       7 . The heat exchanger of  claim 6  wherein said stress relief blind slots are placed in staggered relationship with respect to each other. 
   
   
       8 . The heat exchanger of  claim 6  further comprising a plurality of stress relief blind slots provided in said second type of foam element. 
   
   
       9 . A heat exchanger, comprising:
 a heat exchanger frame having a first end plate, a second end plate placed in opposed relationship with respect to said first end plate and at least one side bar member placed at each end of said first end plate and said second end plate;   a thermally-conductive fluid barrier having first and second surfaces provided in said heat exchanger frame;   at least one first type of foam element placed in thermally-conductive contact with said first surface of said thermally-conductive fluid barrier and having a first coefficient of thermal expansion;   at least one second type of foam element placed in thermally-conductive contact with said second surface of said thermally-conductive fluid barrier and having a second coefficient of thermal expansion; and   wherein said first coefficient of thermal expansion of said first type of foam element and said second coefficient of thermal expansion of said second type of foam element are substantially different.   
   
   
       10 . The heat exchanger of  claim 9  wherein said first type of foam element comprises a reticulated metal foam layer. 
   
   
       11 . The heat exchanger of  claim 10  wherein said reticulated metal foam layer comprises reticulated aluminum foam. 
   
   
       12 . The heat exchanger of  claim 9  wherein said second type of foam element comprises a thermally conductive carbon foam layer. 
   
   
       13 . The heat exchanger of  claim 12  wherein said thermally conductive carbon foam layer is segmented in multiple sections. 
   
   
       14 . The heat exchanger of  claim 9  further comprising a plurality of stress relief blind slots provided in said first type of foam element. 
   
   
       15 . The heat exchanger of  claim 14  wherein said stress relief blind slots are placed in staggered relationship with respect to each other. 
   
   
       16 . The heat exchanger of  claim 14  further comprising a plurality of stress relief blind slots provided in said second type of foam element. 
   
   
       17 . A mixed carbon foam/metallic foam heat exchanger method, comprising:
 providing a reticulated metal foam layer;   providing a thermally conductive carbon foam layer in thermally-conductive contact with said reticulated metal foam layer;   distributing a first fluid through said reticulated metal foam layer; and   distributing a second fluid through said thermally conductive carbon foam layer.   
   
   
       18 . The method of  claim 17  wherein said reticulated metal foam layer comprises a reticulated aluminum foam layer. 
   
   
       19 . The method of  claim 17  further comprising a plurality of stress relief blind slots in said reticulated metal foam layer. 
   
   
       20 . The method of  claim 17  further comprising a plurality of stress relief blind spots in said thermally conductive carbon foam layer.