# Patent

## Title
Foil structure for regenerators

## Abstract

In a regenerator for a regenerative cycle machine, regenerator foil is grooved on both sides, with intersections of grooves on opposite side forming holes at which separate flows of fluid interact to induce flows ancillary to the overall direction of flow in the regenerator, thereby enhancing heat transfer to and from the material of the regenerator and improving thermodynamic performance of the gas cycle machine.

## Background
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a division of application Ser. No. 09/903,302, filed Jul. 10, 2001, now U.S. Pat. No. 6,854,509 issued Feb. 15, 2005.


GOVERNMENT RIGHTS
The invention was made with Government support under contract F29601-99-C-0171 awarded by the United States Air Force. The Government has certain rights in the invention.


BACKGROUND
1. Field of Invention
This invention relates to foil for regenerators of regenerative gas cycle machinery.
2. Description of Prior Art
Regenerative gas cycle machines are a class of machinery that includes Stirling cycle engines and Stirling cycle, Gifford-McMahon, Vuilleumier, Solvay and pulse tube refrigerators. A regenerator is a critical component of all regenerative gas-cycle machines. The regenerator acts as a thermal sponge. Fluid passing back and forth through the regenerator leaves heat in the regenerator matrix in one direction of flow and picks up that heat as it passes back through the regenerator in the opposite direction.
Stacks of wire-mesh screens, wire felt materials, and beds of packed metal powder have been widely used as regenerators in gas cycle machinery because the materials are primarily used for other purposes, are produced in quantity, and are readily available in the marketplace. However, none of those materials is specifically designed to fulfill the special function of a regenerator. Regenerators fabricated from those materials all contain random fluid flow passages in the spaces between wires or grains of powder. The flow passages are of varying width, and a significant portion of the void volume in those regenerator is in spaces in which there is little or no fluid flow and thus little opportunity for heat transfer between the fluid and the regenerator matrix material. One advantage of those prior art materials was that the regenerator permitted lateral flows as well as flows in the overall direction of flow in the regenerator. That permitted imbalances in flow at different points in each cross section of the regenerator to be equalized by natural cross-flows. However, these materials contain no means for dynamically redistributing fluid laterally relative to the overall direction of flow in the regenerator.
Spaced layers of foil have also been used as the matrix material in regenerators in gas cycle machinery. Sheets of foil can be etched to create grooves on the surface of the foil. Foil can also be shaped by crimping or dimpling it, which avoids the loss of material in the etching process, but those techniques have not been sufficiently precise to produce acceptable regenerators. Moreover, solid layers of foil prevent cross-flows necessary to rebalance overall flow distribution over a cross section of the regenerator as fluid moves through it.
Etched foil regenerators used heretofore have partially solved the problem of flow passage width; if the foil is prepared carefully, flow passages are close to the same width throughout the regenerator. Perforations in etched foil have also permitted cross-flows, as in screen, felt and packed powder regenerators. In practice, performance of prior art foil regenerators has generally been disappointing.
Laboratory work with prior art foil regenerators shows that they offer lower pressure drop than felted material, stacked screens or packed powder, the standard regenerator materials. Computer models suggest that prior art foil regenerators should also provide good heat transfer, and, overall, superior performance.
Disappointing performance of prior art foil regenerators is due in part to inadequate heat transfer between the fluid and the foil. When fluid passes straight through the regenerator from one end to the other, the time that the fluid spends in transit is minimized, limiting the time during which heat transfer can take place. Moreover, boundary layers develop as fluid flows through the regenerator, impeding heat transfer.
SUMMARY OF INVENTION
In accordance with the present invention, a regenerator foil contains grooves on both surfaces, with the grooves intersecting each other to form openings through the foil and with the grooves oriented so as to produce secondary motions in the fluid in one or both sets of grooves. Those secondary motions enhance heat transfer between fluid and foil, thereby improving the performance of the regenerator. Those secondary motions also tend to continually redistribute fluid throughout the whole regenerator in a direction lateral to the overall direction of flow through the regenerator.
Multiple layers of stainless steel foil prepared according to this invention can be used as the heat sink medium for a regenerator with a cold end that operates at temperatures above about 35 Kelvin. Layers of stainless steel foil prepared according to this invention can also be interspersed between layers of other materials with greater heat capacity than stainless steel at temperatures below about 35 Kelvin. By employing foil of this invention as spacer material between layers of foil fabricated from alloys of rare earth (Lanthanide) elements, a regenerator effective to temperatures below 10 Kelvin may be fabricated.
OBJECTS AND ADVANTAGES
Several objects and advantages of this invention are:

    (1) To provide high performance foil regenerators for use in gas cycle machines.
    (2) To provide easily-fabricated elements from which foil regenerators may be assembled.
    (3) To provide practical high-performance regenerators for coolers operating at temperatures below 30 Kelvins.
    (4) To provide high performance foil regenerators for use in coaxial pulse tube refrigerators.
    (5) To provide foil regenerators containing materials with high heat capacities at temperatures within a few Kelvins of absolute zero.
    (6) To provide regenerators with high heat transfer rates induced by controlled secondary fluid flows.


Further objects and advantages will become apparent from a consideration of the ensuing description and drawings.



DRAWING FIGURES
FIG. 1 is a schematic view of a prior art coaxial pulse tube refrigerator.
FIG. 2 is a schematic perspective view of a prior art foil regenerator for a coaxial pulse tube cooler.
FIG. 3 is a schematic perspective view of a prior art foil regenerator, spiral-wrapped on a mandrel.
FIG. 4 is a schematic view of a piece of prior art etched regenerator foil.
FIG. 5 is a schematic representation of flow in the grooves of a piece of regenerator foil of FIG. 4.
FIG. 6A is a schematic perspective view of a piece of regenerator foil of this invention with constant-slant grooves.
FIG. 6B is a schematic view of a piece of regenerator foil of this invention with zigzag-slant grooves.
FIG. 7 illustrates blockage of grooves in a piece of prior art etched regenerator foil.
FIG. 8A illustrates flow in grooves in a piece of regenerator foil of this invention with zigzag spacers.
FIG. 8B illustrates flow in grooves in a piece of regenerator foil of this invention with constant-slant spacers.



REFERENCE NUMERALS IN DRAWINGS


    50 compressor
    52 piston
    54 compression space
    56 aftercooler
    58 housing
    60 regenerator
    62 cold heat exchanger
    64 pulse tube
    66 warm heat exchanger
    68 orifice
    70 reservoir
    80 multiple layers of foil
    82 central opening
    84 mandrel
    90 strip
    92 slit
    94 spacer-strap
    96 groove, front side
    98 groove, back side
    99 unetched spacers
    100 angled spacer-strap
    120 heat exchanger fin
    122 heat exchanger slot
    124 open groove
    126 blocked groove
    132 solid foil


Definitions: For purposes of this patent, “foil” means sheets of material that are thin relative to their other dimensions. “Surface” as applied to foil means one of the two surfaces of relatively large area, as distinguished from the edges, whose short dimension is approximately the thickness of the foil. “Grooved foil” means foil that has been sculpted, by photoetching or any other process, so that it has grooves on both sides, with the grooves on one side intersecting the grooves on the other side, forming holes in the foil at the places where grooves on opposite sides of the foil intersect. “Continuous” as applied to a groove means a groove at least as long as one complete wrap around a spiral-wrapped regenerator, or spanning from edge to edge of a piece of flat foil in a regenerator assembled from multiple separate pieces of foil. “Solid foil” means foil that has not been grooved or perforated. “Overall direction of flow” in a regenerator is the direction of a line drawn from the center of the end of a regenerator where fluid enters to the center of the end of the regenerator where fluid exits, in either direction of flow; individual parcels of fluid moving in the regenerator may follow other paths without altering the overall direction of flow.
DESCRIPTION—FIGS. 1–5—PRIOR ART
FIG. 1 is a schematic illustration of a prior-art coaxial pulse tube refrigerator. Compressor 50 has a piston 52 that cyclically alters the volume of compression space 54, forcing fluid into and out of other components of the refrigerator including aftercooler 56, regenerator 60, cold heat exchanger 62, pulse tube 64, warm heat exchanger 66, and orifice 68 through which fluid passes into and out of reservoir 70. Although compressor 50 is shown with piston 52, alternate methods of generating cyclically varying pressure, such as a valved compressor, are equivalent.
As fluid flows back and forth through regenerator 60, it leaves heat in the regenerator material as it flows in one direction and picks up heat from the regenerator material as it flows back in the other direction. The material of the regenerator must be porous to permit fluid to flow, and the size and shape of the flow passages determines both the effectiveness of heat transfer between regenerator material and fluid and the amount of pressure drop experienced by the flow. FIG. 2 shows detail of a regenerator comprised of multiple layers of foil 80, with a central opening 82, and suited for use in the coaxial pulse tube refrigerator of FIG. 1.
FIG. 3 is a schematic cross section of a prior-art spiral-wrapped foil regenerator according to U.S. Pat. No. 5,429,177. Regenerator foil 61 is wrapped around a mandrel 84 which may be solid or may be a hollow tube that surrounds, or serves as, the pulse tube in the coaxial pulse tube refrigerator of FIG. 1. An outer layer may be solid foil 132.
FIG. 4, prior art, illustrates a portion of a piece of regenerator foil of the general prior art type illustrated in FIG. 13 in U.S. Pat. No. 5,429,177. The foil is etched from both sides to create relatively short grooves normal to the overall direction of flow. The grooves are interrupted by spacer-straps 94 of foil that has not been etched completely through; spacer straps 94 hold the piece of foil together. Grooves 96 are entirely on the front side of the foil as drawn. Grooves 96 are arranged in a zigzag pattern relative to the overall direction of flow in the regenerator.
FIG. 5, prior art, illustrates flow patterns in one direction of flow in the grooves on the surface of the foil of FIG. 4. The large arrows indicate the principal flow, which follows a zigzag path in the grooves, front side 96 of FIG. 4 between the zigzag spacers of FIG. 4. The small arrows in FIG. 5 show small induced flows in slits 92 of FIG. 4.
FIG. 6A shows the structure of a portion of a piece of regenerator foil of this invention. The overall direction of flow in the regenerator is between the top and bottom edges of the piece as shown. Strips 90 normal to the overall direction of flow comprise the back side of the piece of foil. Spacers 100 on the front side of the piece of foil are angled relative to the overall direction of flow, and relative to strips 90 on the back side. In practice, the etching process rounds the sharp edges shown schematically in FIG. 6A.
FIG. 6B shows an alternate structure of a portion of a piece of regenerator foil of this invention. The overall direction of flow in the regenerator is between the top and bottom edges of the piece as shown. Strips 90 normal to the overall direction of flow comprise the back side of the piece of foil. Spacer straps 94 on the front side of the piece of foil are again angled relative to the overall direction of flow, and relative to the strips 90 on the back side of the piece of foil, but instead of stretching diagonally across the whole piece of foil, the slant of the spacer straps 94 periodically reverses. The reversal of direction occurs where spacer straps 94 cross the slits 92 between strips. Grooves 98 on the back side pass under spacer straps 94 which remain unetched on the front side.
FIG. 7 illustrates blockage of grooves in a piece of prior art regenerator foil where a prior art foil regenerator meets heat exchanger comprised of a block of metal fabricated to leave heat exchanger fins 120 on either side of heat exchanger slot 122. Grooves 124 are open to heat exchanger slot 122 but grooves 126 terminate against heat exchanger fins 120.
FIG. 8A illustrates flow patterns in one direction of flow in the grooves in the foil of FIG. 6B. The largest arrows indicate the principal flow, which follows a zigzag path in the grooves, front side 96 of FIG. 6B. The horizontal arrows show uninterrupted induced flows in grooves, back side 98 of FIG. 6B. The curved arrows indicated smaller flows periodically entering and leaving the continuous horizontal flow.
FIG. 8B illustrates flow patterns in one direction of flow in the grooves in the foil of FIG. 6A. The largest arrows indicate the principal flow, which follows a diagonal path in the grooves, front side 96 of FIG. 6A. The horizontal arrows show uninterrupted induced flows in grooves, back side 98, of FIG. 6B. The curved arrows indicated smaller flows periodically entering and leaving the continuous horizontal flow on the back side.
DESCRIPTION AND OPERATION
The basic principle of this invention is that grooves on opposite sides of a sheet of foil are oriented in such a way that when fluid flows in grooves on one side of the sheet, motion is imparted to fluid in grooves on the opposite side of the sheet. The motion imparted to fluid in grooves on the opposite side of the sheet is “induced flow”. Induced flow enhances heat transfer, and thereby improves the performance of the regenerator.
In one embodiment of this invention, successive layers of foil embody the same structure. Flows in grooves on both sides of each layer interact with flows on the facing sides of adjacent layers. In that embodiment, the induced flow is in grooves normal to the overall direction of flow.
In preferred embodiments of regenerator foil, the foil structure is obtained by photoetching grooves on both sides of a sheet of stainless steel foil. Since the etching process goes deeper than 50% of the way through the foil, the foil is etched completely through its whole thickness at locations where grooves intersect. However, other methods of fabrication are equivalent if the end result is foil with grooves on both sides and holes where the grooves intersect.
Imperfections in the interface between a regenerator and the heat exchangers at its ends tend to generate significant losses in performance of gas cycle machines. For example, a useful type of cold heat exchanger can be fabricated by cutting slots in a cylindrical copper block. Typically, that type of heat exchanger has wide fins between slots. Features on the regenerator are typically on a far smaller scale; the ends of the heat exchanger fins tend to contact a relatively large area at the end of a regenerator, blocking flow at the points of contact and channeling flow to a relatively small portion of the cross section of the end of the regenerator, as shown in FIG. 7. The resulting imbalance in flow distribution across the cross section of the regenerator causes thermodynamic losses. The regenerator foil of this invention reduces those losses.
In operation of this invention, flow entering at the edge of the foil through an unblocked groove will be driven through a slant groove 96 in FIGS. 6A and 6B until it reaches a groove oriented normal to the overall direction of flow through the regenerator. There, the flow will be forced to either change direction sharply to move into the next slant groove or to change direction less radically to move into a groove oriented normal to the overall direction of flow. The effect will be to drive the flow strongly through the circumferential groove 98 in FIGS. 6A and 6B, distributing it around the whole circumference of a layer of regenerator foil in a regenerator such as is shown in FIG. 1.
In foil shown in FIG. 6B, flow must reverse in order to move from a groove normal to the overall direction of flow into the next row of slant grooves. Again, at the end of the next slant grooves, fluid is forced into a circumferential groove from which it eventually emerges, with a change of direction, into yet another row of slant grooves. The flow-reversal process is repeated to ensure even distribution of flow between parallel axial grooves. The pattern shown in FIG. 6B may be repeated across the entire width of a foil in the overall direction of flow or a prior art pattern such as is shown in FIG. 4 or FIG. 7 may be used in the middle of the foil, away from the edges.
In addition to its basic function of redistributing flow, the slant groove pattern enhances regenerator performance in at least two ways. First, by lengthening the flow path of the slant groove relative to the path of an axial groove this invention lengthens the flow distance, increasing heat transfer effectiveness. Second, by driving a flow through the grooves normal to the overall direction of flow, forced convection between fluid and the walls of those grooves is improved, which again enhances heat transfer.
CONCLUSION, RAMIFICATIONS, AND SCOPE
This invention improves upon prior art foil regenerators by employing patterns that force rather than merely permit secondary flows. As a consequence, although the overall direction of flow in a regenerator of this invention is not altered, the flow paths that individual parcels of fluid follow in passing through the regenerator continually redistribute flows circumferentially in an annular regenerator in which each layer is regenerator foil bearing the same pattern of grooves.
Although the description above contains many specifics, these should not be construed as limiting the scope of the invention but merely as providing illustrations of some of the presently preferred embodiments of this invention Thus, the scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given.

## Claims

1. In a regenerator comprising multiple layers of foil, an improvement comprising:
a layer of foil containing a multiplicity of substantially continuous grooves on a first surface thereof and a multiplicity of grooves on a second surface thereof
wherein said substantially continuous grooves on said first surface are oriented normal to the overall direction of flow in said regenerator, and
wherein said grooves on said second surface intersect said grooves on said first surface at an angle other than 90 degrees, and
wherein intersections of said substantially continuous grooves on said first surface and said grooves on said second surface comprise holes in said layer of foil.

2. The improvement of claim 1 wherein said layer of foil is comprised of stainless steel.

3. The improvement of claim 1 wherein said substantially continuous grooves on said first surface are formed by etching.

4. The improvement of claim 3 wherein said grooves on said second surface are formed by etching.

5. The improvement of claim 1 wherein the depth of said substantially continuous grooves on said first surface is between 50% and 60% of the greatest thickness of said layer of foil.

6. The improvement of claim 5 wherein the depth of said grooves on said second surface is between 50% and 60% of the greatest thickness of said layer of foil.