Under funding from the federal Department of Advanced Research Projects Agency (DARPA) the founder of Zess Inc in cooperation with US National Laboratories developed patented applications in the field of micro-channel technology.

  • NREL’s Thermo-Acoustic Automotive Air-Conditioning | View
  • MC Integrated Refrigeration System | View

Micro-Channel Heat Transfer Theory:

As the equivalent diameter  "De" of the flow channels becomes smaller the heat transfer coefficient  "h" increases with laminar flow
h = Nu*k
and the surface area to volume ratio increases dramatically.



Titanium Micro-Channel Intercoolers for Turbo-Charged Engines


  • Maximum effectiveness for high performance sports vehicles, off-track vehicles, and marine intercoolers
  • Non-corrosive, Light weight, Compact size
  • Counter flow design for maximum heat transfer effectiveness

Under federal funding from the National Institute of Standards and Technology (NIST) Zess Inc was tasked with developing a prototype MC inter-cooler for the turbo-charged Cummins engines used in the Bradley Armored Vehicle.


Intercoolers remove heat from the compressed air of a turbocharger or air compressor to increase the mass flow of oxygen to the engine. Increasing the oxygen mass flow rate increase engine efficiency. An increase in effectiveness and reduction in size and weight will result in both an increase in power and fuel savings. Analysis performed by the US National laboratories and prototype testing by Zess Inc predicts the size of the Bradley inter-cooler to be reduced to less than 1/2 to current size with an effectiveness of greater than 90% with the MC intercooler.

National Renewable Energy Laboratories (NREL) Thermo-acoustic Automotive Air-Conditioning

  • Zess Inc is providing micro-channel regenerators for NREL’s development of thermo-acoustic automotive air-conditioning.


Micro Channel Refrigeration systems
Residential and commercial air conditioning, vending machines, and other AC/R units
Typical SEER values for current Package Terminal Air Conditioning (PTAC) units that have conventional coil/fin evaporators and condensers are in the range of 9 to 10 Btuh/watt. However, minimum federal requirements will increase to 12 Btuh/watt.  


As the physical size of PTAC units are fixed in order to fit wall-opening clearances the coil-fin condenser and evaporator heat exchangers cannot be enlarged to further improve efficiency.

The only way to dramatically improve efficiencies of PTAC units and other AC/R systems is to improve the effectiveness of the evaporator and condenser heat exchangers.


"The MCRS is similar to going from the individual transistor to the integrated circuit"

 Image  Zess Inc is developing an integrated micro-channel refrigeration system in place of the conventional coil fin evaporator and condenser for residential and commercial AC units. With this revolutionary approach, the micro-channel refrigeration system (MCRS) combines the components of an AC/R system (evaporator and condenser) into a single micro-refrigeration component consisting of numerous microchannel subassemblies. Having high heat transfer coefficients and large surface area to volume ratios inherent to micro-channel technology, the integrated MC refrigeration systems for PTAC units are projected to reach EER values exceeding 15 Btuh/watt.

Fuel Cells

A number of ultra-compact heat exchangers, requiring zero leakage, high effectiveness, and reliability are required in typical PEM or other type fuel cells.


For further information or to discuss how MC Heat Exchangers can be the answer for your system contact us:
Zess Inc at 877.658.0383
or email:

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