Enhanced Cooling Breakthrough Nearly Doubles Efficiency and Performance in Energy Systems

new Solid-State Cooling Tech Achieves Double the Efficiency of Current Systems

september 20, 2025

Laurel, Maryland – Scientists at the Johns Hopkins Applied Physics Laboratory (APL) have unveiled a transformative solid-state refrigeration technology that substantially outperforms existing methods. This innovation, reliant on advanced nano-engineered materials, boasts double the efficiency of commercially available thermoelectric cooling systems, offering a potential solution to the escalating global demand for sustainable cooling.

The advancement stems from collaborative efforts between APL researchers and engineers from Samsung Research, as detailed in a recent publication in Nature Communications. The core of this leap forward lies in “controlled hierarchically engineered superlattice structures” (CHESS), a high-performance nano-engineered material developed at APL.

Decade of Growth Culminates in Breakthrough

The CHESS technology is the result of a decade-long undertaking at APL, initially driven by national security requirements.It has since found application in non-invasive cooling therapies for prosthetic limbs, earning an R&D 100 award in 2023. Rama Venkatasubramanian, Chief Technologist for Thermoelectrics at APL and principal investigator on the project, emphasized the technology’s potential to reshape the landscape of cooling applications.

“This presentation showcases the power of nano-engineered CHESS thin films and represents a pivotal step towards practical,large-scale,energy-efficient refrigeration,” Venkatasubramanian stated.

Addressing a Growing Global Need

Rising populations, increasing urbanization, and the proliferation of advanced electronics are driving an urgent need for more effective cooling solutions. Traditional refrigeration systems,while prevalent,often suffer from bulkiness,high energy consumption,and the use of environmentally damaging chemical refrigerants. According to a recent report by the International energy Agency, space cooling alone could account for 13% of global electricity demand by 2050. https://www.iea.org/reports/cooling-outlook-2023

Thermoelectric refrigeration offers a promising choice. By leveraging electrons to transfer heat via specialized semiconductor materials, it eliminates the need for moving parts and harmful chemicals, resulting in quieter, more compact, and sustainable units.

Performance Gains Validated by Samsung Research

rigorous testing, conducted in standardized refrigeration environments, compared modules utilizing conventional thermoelectric materials with those employing CHESS thin-film materials. Researchers meticulously measured electrical power consumption for varying cooling levels. Samsung Research’s Life Solution Team, led by Executive Vice President Joonhyun Lee, performed detailed thermal modeling to validate the results, confirming the accuracy of performance evaluations.

The outcomes were pronounced. Devices incorporating CHESS materials demonstrated nearly a 100% improvement in efficiency at room temperature (approximately 77 degrees Fahrenheit or 25 degrees Celsius) compared to their traditional counterparts. This translated to approximately a 75% enhancement at the device level and a 70% increase within a fully integrated refrigeration system.

Scalability and Manufacturing Advantages

Beyond its superior performance,the CHESS thin-film technology drastically reduces material requirements-using merely 0.003 cubic centimeters per refrigeration unit, equivalent to the size of a grain of sand.This minimal material usage, coupled with compatibility with existing semiconductor chip fabrication processes, promises cost-effective mass production.

Venkatasubramanian suggests the technology’s potential extends far beyond small-scale refrigeration. “This thin-film technology has the potential to scale toward supporting large building HVAC applications, mirroring the trajectory of lithium-ion batteries-from powering mobile phones to electric vehicles.”

The manufacturing process itself utilizes metal-organic chemical vapor deposition (MOCVD),a technique already widely employed in the production of high-efficiency solar cells and LED lighting. Jon Pierce, a Senior Research Engineer at APL, highlighted the benefits of this established methodology.”MOCVD is ideal for scaling up CHESS production, thanks to its cost-effectiveness and capacity for large-volume manufacturing.”

Feature	Traditional Thermoelectric Materials	CHESS Thin-Film Materials
Efficiency Improvement (Room Temp)	Baseline	~100%
Device-Level Efficiency Improvement	Baseline	~75%
System-Level Efficiency Improvement	Baseline	~70%
Material Usage	Significant	Minimal (grain of sand sized)

Did You Know? Thermoelectric refrigeration, while promising, historically faced limitations due to the low efficiency and scalability of bulk materials. the CHESS technology directly addresses these challenges.

APL intends to continue refining the CHESS materials, aiming to achieve efficiencies comparable to conventional mechanical systems. Future plans involve demonstrating larger-scale systems, including freezers, and integrating artificial intelligence to optimize energy efficiency in complex cooling applications.

Jeff Maranchi, Exploration Program Area manager at APL, noted the versatility of CHESS materials.”Beyond refrigeration, CHESS materials can convert temperature differences – such as body heat – into usable power, opening doors for energy harvesting applications in computers, spacecraft, and advanced prosthetics.

“This collaborative success demonstrates that high-efficiency solid-state refrigeration isn’t merely a scientific concept; it is indeed now demonstrably manufacturable at scale,” said Susan Ehrlich, an APL technology commercialization manager.

The Future of Cooling: A Deeper Dive

The development of CHESS materials marks a significant stride in the field of thermoelectricity, a technology that offers a pathway to more sustainable and efficient energy solutions. While the initial focus is on refrigeration,the underlying principles of converting thermal energy into electrical energy and vice versa have broader implications. Advancements in thermoelectric materials could potentially revolutionize waste heat recovery, turning otherwise lost energy into usable power. https://www.energy.gov/science-innovation/technology-topics/energy-efficiency/thermoelectrics

Pro Tip: When assessing the environmental impact of cooling technologies, consider not only energy consumption but also the lifecycle of the refrigerants used. thermoelectric systems, by eliminating the need for traditional refrigerants, offer a significant advantage in this regard.

What other industries could benefit from this breakthrough in thermoelectric cooling? How will the scalability of this technology impact its adoption rate?

Frequently Asked Questions About Thermoelectric Cooling

• What is thermoelectric cooling? Thermoelectric cooling uses the Peltier effect to create a temperature difference by transporting heat via electricity, without requiring moving parts.
• How does the CHESS technology improve upon existing thermoelectric materials? CHESS materials are nano-engineered to have significantly higher efficiency and heat-pumping capacity than traditional bulk thermoelectric materials.
• Is this technology commercially available now? While not yet widely available, APL is actively seeking partnerships to scale up production and bring this technology to market.
• What are the potential applications beyond refrigerators? potential applications include HVAC systems, waste heat recovery, and even powering devices with body heat.
• How does the manufacturing process contribute to the scalability of CHESS materials? The use of MOCVD, a widely used and cost-effective manufacturing technique, allows for large-volume production.
• What is the environmental impact of this new technology? Eliminating the need for harmful chemical refrigerants and reducing energy consumption significantly lowers the environmental impact.

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how do nanofluids enhance heat transfer compared to customary cooling fluids like water or glycol?

The Science Behind the Leap in Thermal Management

Recent advancements in materials science and engineering have yielded a significant breakthrough in cooling technology, promising to nearly double the efficiency and performance of various energy systems. This isn’t simply an incremental improvement; it represents a paradigm shift in how we approach thermal management, impacting everything from data centers and power generation to electric vehicles and renewable energy infrastructure. The core of this innovation lies in the progress of novel heat transfer fluids and microchannel heat exchangers.

Novel Heat Transfer Fluids: Beyond Water and Glycol

Traditional cooling systems rely heavily on water or glycol-based fluids. While effective to a degree, these fluids have limitations in terms of heat capacity, thermal conductivity, and operating temperature range. The new generation of heat transfer fluids utilizes nanofluids – fluids containing nanoparticles – to dramatically enhance these properties.

* Nanoparticle Composition: Common nanoparticles include metal oxides (aluminum oxide, copper oxide), carbon nanotubes, and graphene. The choice of nanoparticle depends on the specific application and desired thermal characteristics.

* Enhanced Thermal Conductivity: Nanoparticles considerably increase the fluid’s ability to conduct heat, leading to faster and more efficient heat removal.Studies show improvements ranging from 20% to 40% in thermal conductivity compared to base fluids.

* Improved Heat Capacity: Certain nanofluids exhibit higher heat capacity, allowing them to absorb more heat with a smaller volume of fluid.

* Reduced Viscosity: Maintaining low viscosity is crucial for efficient pumping and flow. Researchers are focusing on surface modification of nanoparticles to prevent agglomeration and minimize viscosity increases.

Microchannel Heat Exchangers: Maximizing Surface Area

Complementing the advanced fluids are microchannel heat exchangers. These devices feature tiny channels – typically less than 1 millimeter in diameter – etched into a solid material (often copper or aluminum).

* Increased Surface Area-to-Volume Ratio: The small channel size dramatically increases the surface area available for heat transfer, leading to significantly higher heat transfer rates.

* Reduced Thermal Resistance: The short diffusion paths within the microchannels minimize thermal resistance, further enhancing heat removal.

* Compact Design: Microchannel heat exchangers are significantly smaller and lighter than conventional heat exchangers, making them ideal for applications with space constraints.

* Flow Characteristics: Maintaining uniform flow distribution within the microchannels is critical. Advanced manufacturing techniques, such as micro-molding and etching, are employed to ensure optimal flow characteristics.

Applications Across Diverse Energy sectors

The implications of this enhanced cooling technology are far-reaching, impacting a wide range of industries.

Data Centers: Reducing PUE and Operational Costs

Data centers are notorious energy hogs, with a significant portion of their energy consumption dedicated to cooling. Implementing these new cooling solutions can drastically reduce the Power Usage effectiveness (PUE) – a key metric for data center efficiency.

* High-Density Computing: The improved cooling capacity enables higher component densities, allowing for more processing power within the same footprint.

* Reduced fan Energy: More efficient heat removal reduces the need for energy-intensive fans, lowering operational costs and carbon emissions.

* Liquid Cooling Adoption: this breakthrough accelerates the adoption of liquid cooling technologies, which are becoming increasingly essential for handling the heat generated by advanced processors and GPUs.

Electric Vehicles (EVs): Extending Range and Performance

Thermal management is a critical challenge in EV design. batteries, motors, and power electronics all generate significant heat, which can degrade performance and shorten battery life.

* Battery Thermal Management: Precise temperature control is essential for optimal battery performance and longevity. Enhanced cooling systems can maintain batteries within their ideal operating temperature range, extending range and reducing degradation.

* motor and Inverter Cooling: Efficiently cooling the motor and inverter improves their efficiency and power output.

* Fast Charging Capabilities: Improved cooling allows for faster charging rates without overheating the battery.

Renewable Energy: Boosting Efficiency and Reliability

Renewable energy systems, such as concentrated solar power (CSP) and geothermal plants, often operate at high temperatures and require robust cooling solutions.

* CSP Plants: Enhanced cooling can improve the efficiency of power generation in CSP plants by allowing for higher operating temperatures.

* Geothermal Power Plants: Efficient heat exchangers are crucial for extracting energy from geothermal resources.

* wind Turbine Gearboxes: Cooling the gearbox in wind turbines prevents overheating and extends its lifespan.

Benefits of Implementing Advanced Cooling Systems

The advantages of adopting this new cooling technology extend beyond improved efficiency and performance.

* Reduced Energy Consumption: Lower energy consumption translates to significant cost savings and a reduced carbon footprint.

* Increased System Reliability: Maintaining optimal operating temperatures extends the lifespan of critical components, reducing downtime and maintenance costs.

* Higher Power Density: Enables the development of more compact and powerful systems.

* Environmental sustainability: Reduced energy consumption and improved resource utilization contribute to a more sustainable future.

Practical Tips for Implementation

Successfully integrating these advanced cooling solutions requires careful planning and consideration.

1. System Analysis: Conduct a thorough thermal analysis of your system to identify heat sources and determine cooling requirements.
2. Fluid Selection: Choose the appropriate nanofluid based on your specific application and operating conditions.
3. Heat Exchanger Design: Optimize the design of the microchannel heat exchanger to maximize heat transfer and minimize