System for heat transfer optimization using flow identification sensors

Abstract

A thermal management system that uses flow regime identification information obtained from a flow sensor to control heat exchanger operation so it is maintained at or below the Critical Heat Flux point. The flow sensor is integrated with a controller to control the liquid flow rate and temperature inside and/or outside the heat exchanger such that the heat flux stays below the Critical Heal Flux point while at the same time being in the nucleate boiling flow regime.

What is claimed is: 
     
         1 . A heat transfer optimization system comprised of:
 a first heat exchanger;   a flow sensor for obtaining flow regime information or data for fluid flowing through the first heat exchanger;   a flow regulating device for controlling the rate of flow of the fluid flowing through the first heat exchanger; and   a control system that uses flow regime information or data to send control signals to the flow regulating device to control the rate of flow of the fluid flowing through the first heat exchanger to control the rate of heat transfer.   
     
     
         2 . The system of  claim 1 , wherein the system is programmed to keep the fluid flowing through the first heat exchanger at or close to a Critical Heat Flux point. 
     
     
         3 . The system of  claim 1 , wherein the system is configured to control the rate of flow of the fluid flowing through the first heat exchanger to maintain the fluid flowing through the first heat exchanger at or close to a nucleate boiling regime. 
     
     
         4 . The system of  claim 1 , wherein the flow sensor is a multi-dimensional flow sensor or meter comprised of a plurality of capacitance plates. 
     
     
         5 . The system of  claim 1 , further comprising a second heat exchanger or radiator operationally located between the first heat exchanger and the flow regulating device for cooling the fluid exiting the first heat exchanger for circulating it back to the first heat exchanger. 
     
     
         6 . The system of  claim 1 , wherein the first heat exchanger is a metal tube or conduit. 
     
     
         7 . The system of  claim 1 , wherein the flow regulating device is a pump or valve. 
     
     
         8 . The system of  claim 1 , further comprising a fluid pump or valve for controlling the temperature of a fluid outside the first heat exchanger to optimize heat transfer between the fluid outside the first heat exchanger and the fluid flowing through the first heat exchanger. 
     
     
         9 . The system of  claim 1 , wherein the fluid flowing through the first heat exchanger can be a liquid or gas. 
     
     
         10 . The system of  claim 1 , wherein volume fraction information or data is used by the control system to adjust flow rate. 
     
     
         11 . The system of  claim 1 , wherein the flow sensor is comprised of a capacitance sensor and a data acquisition system for obtaining the flow regime information or data. 
     
     
         12 . A heat transfer optimization system comprised of:
 a first heat exchanger;   a flow sensor for obtaining flow regime information for fluid flowing outside the first heat exchanger, wherein the flow sensor is comprised of the first heat exchanger that acts as a first sensor plate of the flow sensor and a plurality of receiver plates configured outside the first heat exchanger;   a first flow regulating device for controlling the rate of flow of the fluid flowing outside the first heat exchanger; and   a control system that uses flow regime information or data obtained by the flow sensor to send control signals to the first flow regulating device to control the rate of flow of the fluid flowing outside the first heat exchanger to control the rate of heat transfer.   
     
     
         13 . The system of  claim 12 , wherein the system is programmed to keep the fluid flowing outside the first heat exchanger at or close to a Critical Heat Flux point. 
     
     
         14 . The system of  claim 12 , wherein the system is a cooling system for electric charging wherein the first heat exchanger is an outer surface of a charging wire, and wherein a coolant flows outside the first heat exchanger and transfers heat generated by the current in the wire to the coolant touching the surface of the wire. 
     
     
         15 . The system of  claim 12 , wherein the system is configured to control the rate of flow of the fluid flowing outside the first heat exchanger to maintain the fluid flowing outside the first heat exchanger at or close to a nucleate boiling regime. 
     
     
         16 . The system of  claim 12 , wherein the flow sensor is a multi-dimensional flow sensor or meter comprised of a plurality of capacitance plates. 
     
     
         17 . A heat transfer optimization system comprised of:
 a first heat exchanger;   a flow sensor for obtaining flow regime information or data for fluid flowing through the first heat exchanger and for fluid flowing outside the first heat exchanger;   a first flow regulating device for controlling the rate of flow of the fluid flowing through the first heat exchanger;   a control system that uses flow regime information or data to send control signals to the first flow regulating device to control the rate of flow of the fluid flowing through the first heat exchanger to control the rate of heat transfer; and   a second flow regulating device for controlling the rate of flow of the fluid flowing outside the first heat exchanger;   wherein the control system uses flow regime information or data to send control signals to the second flow regulating device to control the rate of flow of the fluid flowing outside the first heat exchanger to control the rate of heat transfer.   
     
     
         18 . The system of  claim 17 , wherein the system is programmed to keep the fluid flowing through the first heat exchanger at or close to a Critical Heat Flux point. 
     
     
         19 . The system of  claim 17 , wherein the system is configured to control the rate of flow of the fluid flowing through the first heat exchanger to maintain the fluid flowing through the first heat exchanger at or close to a nucleate boiling regime. 
     
     
         20 . The system of  claim 17 , further comprising:
 a second heat exchanger or radiator operationally located between the first heat exchanger and the first flow regulating device for cooling the fluid flowing through the second heat exchanger and wherein the second heat exchanger cools the fluid exiting the first heat exchanger to circulate it back to the first heat exchanger.   
     
     
         21 . The system of  claim 1 , wherein the first heat exchanger is a non-metallic tube or conduit capable of transferring heat from the fluid flowing through the first heat exchanger to the outside environment.