{"id":{"repo_id":"uiuc","oai_identifier":"oai:www.ideals.illinois.edu:2142/110855"},"canonical_url":"https://search.dev.ndltd.org/etd/uiuc/oai:www.ideals.illinois.edu:2142/110855","repository":{"repo_id":"uiuc","name":"University of Illinois - Urbana-Champaign","base_url":"https://www.ideals.illinois.edu/oai-pmh"},"display":{"title":"Design and manufacturing of novel hybrid metal-polymer heat exchangers","abstract":"Nearly 60% of waste heat from industrial processes in the U.S. lies in low-temperature regime (<200°C). Current conventional metal heat exchangers for waste heat recovery (WHR) of low-grade heat are too expensive and subject to corrosion from condensates below <150°C. Polymers, although an attractive alternative to metals, have low thermal conductivity which typically makes them unsuitable for thermal applications. Combining thermally conductive metals with polymers can improve the thermal conductivity of the hybrid to be sufficient for WHR applications. Prior work has explored helically wound metal-polymer hybrid tubes as a means to combine the best aspects of both these materials for suitable heat exchanger performance. Here we show that compared to joining metal strips to polymer strips using laser welding, ultrasonic welding, or resistance seam welding, using adhesives to join the strips is easier for manufacturing and provides adequate joining strength. This work explores the improvement of a roll-to-roll setup to incorporate an adhesive dispensing system to manufacture heat exchanger tubes. To better understand conformal rolling, we develop a theoretical mechanics model to study important forces/factors responsible. Finally, we report data from a real-world demonstration for such heat exchangers within a campus building to analyze the performance and gauge potential under wider operating conditions. This work paves the way for realizing the cost-effective manufacturing of heat exchangers for low-grade WHR.","abstract_html":"Nearly 60% of waste heat from industrial processes in the U.S. lies in low-temperature regime (&lt;200°C). Current conventional metal heat exchangers for waste heat recovery (WHR) of low-grade heat are too expensive and subject to corrosion from condensates below &lt;150°C. Polymers, although an attractive alternative to metals, have low thermal conductivity which typically makes them unsuitable for thermal applications. Combining thermally conductive metals with polymers can improve the thermal conductivity of the hybrid to be sufficient for WHR applications. Prior work has explored helically wound metal-polymer hybrid tubes as a means to combine the best aspects of both these materials for suitable heat exchanger performance. Here we show that compared to joining metal strips to polymer strips using laser welding, ultrasonic welding, or resistance seam welding, using adhesives to join the strips is easier for manufacturing and provides adequate joining strength. This work explores the improvement of a roll-to-roll setup to incorporate an adhesive dispensing system to manufacture heat exchanger tubes. To better understand conformal rolling, we develop a theoretical mechanics model to study important forces/factors responsible. Finally, we report data from a real-world demonstration for such heat exchangers within a campus building to analyze the performance and gauge potential under wider operating conditions. This work paves the way for realizing the cost-effective manufacturing of heat exchangers for low-grade WHR.","abstract_has_math":false,"creators":["Somani, Akhilesh Sanjay"],"institution":"University of Illinois at Urbana-Champaign","degree_name":"M.S.","degree_level":"Thesis","degree_discipline":"Mechanical Engineering","degree_department":null,"school":null,"contributors":["Sinha, Sanjiv"],"advisors":[],"committee_chairs":[],"committee_members":[],"year":2021,"date_issued":"2021-09-17T04:06:52Z","date_published":"2021-09-17T04:06:52Z","updated_at":"2026-07-22T22:24:52Z","subjects":["waste heat recovery","metal","polymer","helically wound","heat exchanger","adhesives","roll-to-roll","mechanics model","real-world demonstration"],"languages":["en"],"rights":["Copyright 2021 Akhilesh Sanjay Somani"],"rights_urls":[],"identifier_entries":[]},"links":{"outbound_url":"http://hdl.handle.net/2142/110855","outbound_label":"Handle","outbound_source":"dc:identifier"},"metadata_groups":[{"id":"people","label":"People","entries":[{"key":"dc:contributor","label":"Contributor","values":["Sinha, Sanjiv"]},{"key":"dc:creator","label":"Author","values":["Somani, Akhilesh Sanjay"]}]},{"id":"academic_context","label":"Academic Context","entries":[{"key":"dc:date","label":"Dc Date","values":["2021-09-17T04:06:52Z","2023-09-17T04:07:01Z","2021-04-27","2021-05"]},{"key":"dc:type","label":"Dc Type","values":["text","Thesis"]},{"key":"thesis:degree_discipline","label":"Discipline","values":["Mechanical Engineering"]},{"key":"thesis:degree_level","label":"Degree Level","values":["Thesis"]},{"key":"thesis:degree_name","label":"Degree Name","values":["M.S."]},{"key":"thesis:institution_name","label":"Thesis Institution Name","values":["University of Illinois at Urbana-Champaign"]}]},{"id":"subjects_keywords","label":"Subjects and Keywords","entries":[{"key":"dc:subject","label":"Dc Subject","values":["waste heat recovery","metal","polymer","helically wound","heat exchanger","adhesives","roll-to-roll","mechanics model","real-world demonstration"]}]},{"id":"language_rights","label":"Language and Rights","entries":[{"key":"dc:language","label":"Dc Language","values":["en"]},{"key":"dc:rights","label":"Dc Rights","values":["Copyright 2021 Akhilesh Sanjay Somani"]}]},{"id":"identifiers","label":"Identifiers","entries":[{"key":"dc:identifier","label":"Identifier","values":["http://hdl.handle.net/2142/110855"]}]},{"id":"additional","label":"Additional Metadata","entries":[{"key":"dc:description","label":"Description","values":["Nearly 60% of waste heat from industrial processes in the U.S. lies in low-temperature regime (<200°C). Current conventional metal heat exchangers for waste heat recovery (WHR) of low-grade heat are too expensive and subject to corrosion from condensates below <150°C. Polymers, although an attractive alternative to metals, have low thermal conductivity which typically makes them unsuitable for thermal applications. Combining thermally conductive metals with polymers can improve the thermal conductivity of the hybrid to be sufficient for WHR applications. Prior work has explored helically wound metal-polymer hybrid tubes as a means to combine the best aspects of both these materials for suitable heat exchanger performance. Here we show that compared to joining metal strips to polymer strips using laser welding, ultrasonic welding, or resistance seam welding, using adhesives to join the strips is easier for manufacturing and provides adequate joining strength. This work explores the improvement of a roll-to-roll setup to incorporate an adhesive dispensing system to manufacture heat exchanger tubes. To better understand conformal rolling, we develop a theoretical mechanics model to study important forces/factors responsible. Finally, we report data from a real-world demonstration for such heat exchangers within a campus building to analyze the performance and gauge potential under wider operating conditions. This work paves the way for realizing the cost-effective manufacturing of heat exchangers for low-grade WHR.","Submission published under a 24 month embargo labeled 'Closed Access', the embargo will last until 2023-05-01","The student, Akhilesh Sanjay Somani, accepted the attached license on 2021-04-26 at 11:01.","The student, Akhilesh Sanjay Somani, submitted this Thesis for approval on 2021-04-26 at 11:21.","This Thesis was approved for publication on 2021-04-27 at 17:03.","DSpace SAF Submission Ingestion Package generated from Vireo submission #16551 on 2021-09-16 at 20:14:16","Made available in DSpace on 2021-09-17T04:06:52Z (GMT). No. of bitstreams: 2 SOMANI-THESIS-2021.pdf: 7515359 bytes, checksum: f23d6e0245d4db1d8a3b55090e2e7449 (MD5) LICENSE.txt: 4219 bytes, checksum: ae0c34f8b2f759b356039fe3abc44338 (MD5) Previous issue date: 2021-04-27","Embargo set by: Seth Robbins for item 118701 Lift date: 2023-09-17T04:07:01Z Reason: Author requested closed access (OA after 2yrs) in Vireo ETD system","Author requested closed access (OA after 2yrs) in Vireo ETD system","Limited"]},{"key":"dc:format","label":"Dc Format","values":["application/pdf"]},{"key":"dc:title","label":"Title","values":["Design and manufacturing of novel hybrid metal-polymer heat exchangers"]}]}],"canonical_facts":{"dc:contributor":["Sinha, Sanjiv"],"dc:creator":["Somani, Akhilesh Sanjay"],"dc:date":["2021-09-17T04:06:52Z","2023-09-17T04:07:01Z","2021-04-27","2021-05"],"dc:description":["Nearly 60% of waste heat from industrial processes in the U.S. lies in low-temperature regime (<200°C). Current conventional metal heat exchangers for waste heat recovery (WHR) of low-grade heat are too expensive and subject to corrosion from condensates below <150°C. Polymers, although an attractive alternative to metals, have low thermal conductivity which typically makes them unsuitable for thermal applications. Combining thermally conductive metals with polymers can improve the thermal conductivity of the hybrid to be sufficient for WHR applications. Prior work has explored helically wound metal-polymer hybrid tubes as a means to combine the best aspects of both these materials for suitable heat exchanger performance. Here we show that compared to joining metal strips to polymer strips using laser welding, ultrasonic welding, or resistance seam welding, using adhesives to join the strips is easier for manufacturing and provides adequate joining strength. This work explores the improvement of a roll-to-roll setup to incorporate an adhesive dispensing system to manufacture heat exchanger tubes. To better understand conformal rolling, we develop a theoretical mechanics model to study important forces/factors responsible. Finally, we report data from a real-world demonstration for such heat exchangers within a campus building to analyze the performance and gauge potential under wider operating conditions. This work paves the way for realizing the cost-effective manufacturing of heat exchangers for low-grade WHR.","Submission published under a 24 month embargo labeled 'Closed Access', the embargo will last until 2023-05-01","The student, Akhilesh Sanjay Somani, accepted the attached license on 2021-04-26 at 11:01.","The student, Akhilesh Sanjay Somani, submitted this Thesis for approval on 2021-04-26 at 11:21.","This Thesis was approved for publication on 2021-04-27 at 17:03.","DSpace SAF Submission Ingestion Package generated from Vireo submission #16551 on 2021-09-16 at 20:14:16","Made available in DSpace on 2021-09-17T04:06:52Z (GMT). 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