Delivery device and method of manufacturing the same

Abstract

A heat transfer device and method of manufacturing the same includes an outer shell, an inner core, and a flexible membrane extending from the core to an inner surface of the outer shell. The shell includes a first inlet to receive a first fluid, a second inlet to receive a second fluid, a first outlet through which the first fluid exits the shell, and a second outlet through which the second fluid exits the shell. The core forms a first internal passageway fluidly coupling the first inlet and the first outlet and a second internal passageway fluidly coupling the second inlet and the second outlet. The flexible membrane forms a flexible transition between each of the first and second inlets of the shell and the core and forms a seal to prevent the first fluid in the first internal passageway from flowing into the second internal passageway.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to U.S. Provisional Application No. 63 / 176,987 (filed April 20, 2021) and is a partial continuation of U.S. Patent Application No. 16 / 899,331 (filed June 11, 2020), which is a divisional of U.S. Patent Application No. 15 / 821,729 (filed November 22, 2017), which is a partial continuation of U.S. Patent Application No. 15 / 444,566 (filed February 28, 2017, now U.S. Patent No. 10,175,003). The entire disclosure of these applications is incorporated herein by reference. Technical Field

[0003] The transfer devices and methods of manufacturing thereof described herein relate to devices for transferring heat between different fluids (e.g., liquids and / or gases) without mixing the fluids. Optionally, the devices and methods can be used to transfer components between fluids, but such as by filtering one or more components from one fluid (and allowing the filtered components to pass through a barrier to another fluid). The devices can be additively manufactured. Background Technology

[0004] Cooling devices transfer heat from one fluid to another across or through barriers. An example of a cooling device is an exhaust gas recirculation (EGR) cooler. This cooler transfers heat from the recirculated engine exhaust gas to the coolant, such as water, as exhaust gas and water flow through it. One challenge with these coolers is the use of multiple separate bodies for sealing and retaining the coolant within the cooler. For example, the cooler has a housing in which a core is housed. The core has separate channels for the coolant and exhaust gas. The cooler has sliding joints and O-rings (or other seals) between the housing and the core. These sliding joints and seals are used to retain the coolant within the cooler. These multiple bodies are designed to accommodate extreme temperature variations (and associated thermal expansion) of the housing and core.

[0005] However, these components of the cooler are prone to failure under extreme temperature conditions. This can lead to coolant loss during operation and may require component replacement. Equipment that is less prone to failure and / or replacement is needed. Summary of the Invention

[0006] In one or more embodiments, a heat transfer device is provided, comprising an outer housing, an inner heat transfer core, and a flexible diaphragm connected to and extending from the core to an inner surface of the outer housing. The housing includes: a first inlet for receiving a first fluid; a second inlet for receiving a second fluid; a first outlet through which the first fluid is guided out of the housing; and a second outlet through which the second fluid is guided out of the housing. The core forms a first inner passage and a second inner passage separated from each other. The first inner passage fluidly couples the first inlet to the first outlet, and the second inner passage fluidly couples the second inlet to the second outlet. The flexible diaphragm forms a flexible transition between each of the first and second inlets of the housing and the core. The flexible diaphragm also forms a seal to prevent the first fluid flowing through the first inner passage from flowing into the second inner passage of the core.

[0007] In one or more embodiments, a heat transfer device is provided, comprising an integrally formed of an outer housing, an inner heat transfer core, and a flexible diaphragm connected to and extending from the core to an inner surface of the outer housing. The core has a first inner passage and a second inner passage separate from the first inner passage. The core can transfer heat between a first fluid flowing through the first inner passage and a second fluid flowing through the second inner passage without mixing the first and second fluids. The flexible diaphragm forms a flexible transition between the core and each of the first and second inlets of the housing. The flexible diaphragm also forms a seal to prevent the first fluid from flowing into the second inner passage of the core.

[0008] In one or more embodiments, a method is provided (e.g., for forming a heat transfer device). The method comprises additively manufacturing the heat transfer device by sequentially depositing layers of material on top of each other to form a body having an outer shell, an inner heat transfer core, and a flexible diaphragm, the flexible diaphragm being connected to the core and extending to an inner surface of the outer shell. The shell formed by the sequential deposition of layers has: a first inlet for receiving a first fluid; a second inlet for receiving a second fluid; a first outlet through which the first fluid is guided out of the shell; and a second outlet through which the second fluid is guided out of the shell. The flexible diaphragm formed by the sequential deposition of layers serves as a flexible transition between the core and each of the first and second inlets of the shell. The flexible diaphragm formed by the sequential deposition of layers also serves as a seal to prevent the first fluid from flowing into a second internal passageway of the core. Attached Figure Description

[0009] Referring to the accompanying drawings, the subject matter of the invention can be understood by reading the following description of non-limiting embodiments, in which:

[0010] Figure 1 This illustrates an example of a transmission device;

[0011] Figure 2Show Figure 1 The first cross-sectional view of the device shown in the image;

[0012] Figure 3 A cross-sectional view of a portion of the core of the transmission device according to an embodiment is shown;

[0013] Figure 4 Show Figure 1 Additional cross-sectional views of the device shown in the image;

[0014] Figure 5 Show Figure 1 Another cross-sectional view of the device shown in the image;

[0015] Figure 6 Show Figure 1 Another cross-sectional view of the device shown in the image;

[0016] Figure 7 Show along Figure 1 First cross-sectional view of the transmission device in line 7-7;

[0017] Figure 8 Showing along orthogonal to Figure 1 The second cross-sectional view of the transmission device taken from the plane of line 7-7 in the middle;

[0018] Figure 9 Show along Figure 1 Another cross-sectional view of the conveying device for line 7-7 shown in the figure;

[0019] Figure 10 This is a perspective view of the core of the transmission device according to an embodiment;

[0020] Figure 11 for Figure 10 The cross-sectional view of the core shown in the image;

[0021] Figure 12 Show along Figure 11 The first cross-sectional view of the core of line 12-12 shown in the figure;

[0022] Figure 13 Show along Figure 11 The second cross-sectional view of the core of line 13-13 shown in the figure;

[0023] Figure 14 Show along Figure 11 The third cross-sectional view of the core of line 14-14 shown in the figure;

[0024] Figure 15 Show along Figure 11 The fourth cross-sectional view of the core of line 15-15 shown in the figure;

[0025] Figure 16 According to the embodiment, it has an enlarged area displaying the upper cone and the lower cone. Figure 11 The cross-sectional view of the core shown in the image; and

[0026] Figure 17 A flowchart illustrating an example of a method for creating a delivery device or its components. Detailed Implementation

[0027] At least one embodiment of the invention described herein relates to an integral (e.g., single-body) delivery device that accommodates the thermal expansion of a core via unique flexible diaphragms at the device's inlet and outlet. This flexible diaphragm is more easily displaced than some known sliding joints and / or seals, without creating unacceptable stress in the outer housing (e.g., shell) or core. The delivery device forces a cooling medium (e.g., coolant) through the core without a direct connection between the shell and the core. The cooling medium can be forced through volumes of varying sizes formed (e.g., via additive manufacturing) at different locations between (a) the diaphragm and (b) the shell and core, increasing the pressure on the coolant at locations where more of the core is forced through (relative to some known coolers using sliding seals between the core and shell). The flexible diaphragm can be integrally formed with the core and shell via additive manufacturing to provide a fully integrated wall that allows minimal or no coolant leakage between the core and shell. Printing the shell and core as a single-piece body allows for tight control of the junction between the two geometries (core and shell).

[0028] Alternatively, the core and housing described herein can be formed separately, with the core then placed within the housing. For example, the housing can be cast, additively manufactured, injection molded, etc., and the core can be additively manufactured and placed within the housing. A flexible diaphragm can be formed as part of the housing or the core, or can be formed separately and then placed between the housing and the core. The housing and core can then be welded together to form a fully integrated entity.

[0029] The use of additive manufacturing of flexible diaphragms and / or cores enables cores to be placed in a wide variety of application spaces. Similarly, housings can be manufactured to avoid interference with existing components for retrofit applications.

[0030] The device described herein maximizes or increases the lifespan of the device relative to some known EGR coolers by adapting to thermal cycling without sliding joints. Furthermore, because there are no moving or sliding joints to seal with gaskets, O-rings, etc., the device can withstand extreme temperatures, for example, during no-load operation. No-load operation of an engine involves engine exhaust gas flowing through the device without any cooling medium flowing through it. This condition can expose the device to temperatures exceeding 1,000 degrees Fahrenheit (or 540 degrees Celsius). These temperatures can cause seals in some known cooler devices to fail. These extreme temperatures can also cause extreme thermal expansion that some known tubing or fin designs in cooler devices cannot withstand without failure (due to constraints at the ends of the cooler device). In contrast, the flexible diaphragm of the embodiments of the invention described herein can be bent and adapt to thermal expansion without failure.

[0031] Other embodiments of the invention described herein relate to a core or core body of a transfer device. The core body is designed to have repeating interconnected unit cells that define an internal passage for one fluid through the unit cells and an external passage for another fluid outside the unit cells, without the two fluids physically mixing with each other. For example, the internal passage is not fluidly connected to the external passage. The unit cells have sidewalls between the internal and external passages that allow thermal energy (e.g., heat) to be transferred across the sidewalls from a hotter fluid to a colder fluid. Optionally, the sidewalls may be designed to allow one or more components to be transferred (e.g., filtered) from a first fluid to a second fluid through the sidewalls. Optionally, the first and / or second fluids may contain more than one fluid type, composition, or compound. For example, the first fluid may be a coolant introduced into the internal passage of the core, and the second fluid may be multiple different fluids introduced into the external passage. The multiple different fluids may mix with each other within the core and transfer heat to the coolant through the thin sidewalls.

[0032] The core according to the embodiment has a complex, repeating geometry that separates the fluid and is printable without forming a support structure. The geometry of the core allows for the selection of a relatively large unsupported unit cell size. Compared to smaller unit cells, larger unit cells provide reduced flow resistance and pressure drop through the core (e.g., increased fluid delivery). The unit cells are hollow, so increasing the size of the unit cells can effectively reduce the amount of material deposited during the additive manufacturing process relative to smaller unit cells, thereby increasing printing speed and reducing printing and / or material costs.

[0033] The ability to additively manufacture the core without a supporting structure also allows the core to be formed in a custom shape based on specific applications. In an EGR cooler, the core can be printed to conform to the specific internal volume or external dimensions of the housing. Optionally, during common additive manufacturing processes, the core can be integrally formed with the housing to provide a monolithic (one-piece) EGR cooler. Integral forming of the core and housing eliminates seams between components, which can advantageously eliminate potential leakage paths during the use and operation of the EGR cooler.

[0034] Figure 1 An example of a heat transfer device 100 is shown. The device can be used to transfer energy or components between two media. For example, the device can transfer thermal energy (e.g., heat) from one fluid to another (to cool one fluid) or can transfer components from one fluid to another (to filter components from one fluid). The device includes an outer housing 102 in which an internal heat transfer core and a flexible diaphragm are disposed (both shown in the diagram). Figure 2 (In the middle). The housing has a first inlet 110 for receiving a first fluid 112 and a second inlet 114 for receiving a second fluid 116. The first and second fluids can be gases and / or liquids. For example, the first fluid can be a coolant or cooling medium, such as a heat transfer fluid (e.g., water, refrigerant, other synthetic or natural fluids). The second fluid can be a gas discharged from the engine or another liquid. The second fluid may be warmer than the first fluid before entering the device.

[0035] The housing also includes a first outlet 120 and a second outlet 118, through which a first fluid is guided out of the housing and a second fluid is guided out of the housing through the second outlet. As described herein, the core has internal passageways ( Figure 2 (as shown in the image) and external pathways ( Figure 2 As shown in the diagram, a first fluid flows through the core from a first inlet to a first outlet via the internal passage, and a second fluid flows through the core from a second inlet to a second outlet via the external passage. As the first and second fluids flow through the corresponding internal and external passages, heat can be transferred from the second fluid to the first fluid (across or through the material forming the core). Alternatively, at least a portion of the material forming the core can filter one or more components from the second fluid to the first fluid (or from the first fluid to the second fluid). Optionally, the first fluid may comprise a plurality of different fluids mixed together within the internal passage of the core. Optionally, the second fluid may comprise a plurality of different fluids mixed together within the external passage of the core.

[0036] An internal passage maintains the separation of the first fluid from the second fluid, and an external passage maintains the separation of the second fluid from the first fluid. The internal passage guides the flow of the first fluid from a first inlet to a first outlet. The first outlet guides the first fluid (which has now been heated by the second fluid or has received one or more components from the second fluid) to a device or system that cools (or filters) the first fluid and returns it to the first inlet. The external passage guides the flow of the second fluid from a second inlet to a second outlet. The second outlet guides the second fluid (which has now been cooled by the first fluid or has had one or more components removed and transferred to the first fluid) back to the engine (in an EGR engine) or to another location.

[0037] Figure 2 Show Figure 1 The first cross-sectional view of the device shown in the image. Figure 2 The cross section shown in the figure is along the parallel Figure 1 The planar surface extends through the axial center of the core. The internal heat transfer core 204, located within the housing, comprises a single material structure or material web 201 shaped to form a first internal passage 522 and a second internal passage 524. The first internal passage 522 and the second internal passage 524 of the core are also referred to herein as the internal passage and the external passage, respectively. Alternatively, the core may be formed from multiple material bodies or material webs shaped to form the internal and external passages.

[0038] The device includes a flexible diaphragm 206 connected to the core and extending to the inner surface 208 of the outer housing. The diaphragm is flexible because it can bend or otherwise change shape when receiving a force or displacement greater than that of the housing and / or the core (or receiving the same force or displacement). The diaphragm forms a flexible transition between (a) the first and second inlets of the housing and (b) the core. The flexible diaphragm forms a seal preventing first fluid flowing through the internal passages of the core from flowing into the external passages of the core. The flexible diaphragm can accommodate different changes in the size of the housing and the core due to thermal changes. For example, the housing and the core may expand by different amounts or distances due to their different dimensions (even when the housing and the core are formed as a single unit and made of the same material). The flexible diaphragm can bend due to the different expansion of the housing and the core without tearing or otherwise damaging the seal between the housing and the core. This maintains the separation of the internal and external passages of the core.

[0039] Figure 3 A cross-sectional view of a portion of the core according to an embodiment is shown. Figure 3 The cross section shown in the figure is along the parallel Figure 2The plane is a plane offset from the plane. The internal passage 522 is on one side of the core material body or material web, and the external passage 524 is on the opposite side of the core material body or material web. For example, the material body or material web includes a thin sidewall 210 separating the internal passage from the external passage.

[0040] The sidewalls are portions of unit cells 212 of the core, said unit cells being a repeating geometry throughout the core. The unit cells are interconnected. For example, the core is a structure having multiple connected unit cells. In one or more embodiments, the unit cells have a generally spherical shape defined by the sidewalls, such as those formed by… Figure 3 As indicated by the circular cross-section shown. The shape of the peripheral unit cells positioned along the cylindrical side of the core can be deformed as needed to deviate from a spherical shape to provide the desired overall size and / or shape of the core. In other embodiments, the unit cells may have other shapes, such as cubes, parallelepipeds, or prisms. Internal pathways are defined within the unit cells and extend through the unit cells. External pathways are outside the unit cells and represent unoccupied space between the unit cells.

[0041] like Figure 3 As shown, the internal pathways are separated from the external pathways by the sidewalls. Within the unit cell, the two internal pathways are... Figure 3 The diagonal fill in the diagram is used to clearly show the difference between the internal passage and the external passage surrounding the internal passage in the illustrated cross-sectional view. The sidewalls can be relatively thin, for example, less than 3 millimeters (mm) thick. The sidewalls of the unit cell are at edge 806 ( Figure 10 The first and second fluids are connected to each other at points (as shown in the illustration) to fluidly connect internal passages throughout the core while maintaining physical separation between them. In one embodiment, heat can be transferred between the first and second fluids via sidewalls without mixing any other portions of the first and second fluids together in either the internal or external passages. Alternatively, the sidewalls may include pores that filter one or more components from the second fluid to the first fluid (or from the first fluid to the second fluid) without mixing any other portions of the first and second fluids together in either the internal or external passages. In the illustrated embodiment, the fluid in the internal passages is a gas, such as hot exhaust gas from an engine, and the fluid in the external passages is a coolant, such as water. As the water flows along the external passages through the tortuous path between the unit cells, it can absorb heat from the gas through the sidewalls of the unit cells. Water enters the core along the peripheral surface of the core through inlet opening 214 of the external passages.

[0042] Figure 4 , 5 and 6 contain Figure 1 Additional cross-sectional views of the device shown in the image. Along with... Figure 2 The same plane cuts the cross-sectional view. Figure 4 , 5 A cross-sectional view of Figure 6. The flexible diaphragm has a curved conical shape extending inward from the inner surface of the housing to the core. This conical shape provides a conical transition between the housing and the core. The conical transition can be controlled to vary in length (e.g., distance from the inner surface of the housing to the core) and / or the angle of intersection with the housing and the core, allowing the flexible diaphragm to be incorporated into a variety of shapes for the core and / or housing. The ability to customize the size and / or shape of the flexible diaphragm allows the delivery device to be efficiently designed and packaged for space-constrained applications. For example, while the housing is shown as having a cylindrical shape, the core and / or housing can have another shape, such as a rectangular shape, in which the flexible diaphragm extends between the housing and the core and seals the housing to the core.

[0043] In the illustrated embodiments, the flexible diaphragm is flat. For example, the diaphragm may have a smooth conical shape without corrugations, waves, depressions, protrusions, etc. Alternatively, the diaphragm may have an uneven surface with corrugations, waves, depressions, protrusions, etc.

[0044] As shown, the flexible diaphragm may be thinner than the outer housing. The inner surface 432 of the flexible diaphragm faces the core and is opposite to the inner surface of the housing between the second inlet and the second outlet. This inner surface of the flexible diaphragm may form an angle of less than 45 degrees with the inner surface of the outer housing. Alternatively, this inner surface may form an angle of less than 30 degrees or less than 15 degrees with the inner surface of the outer housing. The opposing outer surface 430 of the flexible diaphragm faces away from the core and may face the inner surface of the housing between the second inlet and the second outlet. This outer surface of the flexible diaphragm may form an angle of greater than 45 degrees with the inner surface of the outer housing. Alternatively, this outer surface may form an angle of greater than 55 degrees or greater than 75 degrees with the inner surface of the outer housing.

[0045] Figure 7 Show along Figure 1 The first cross-sectional view of the transmission device in line 7-7. Figure 8 A second cross-sectional view of the transfer device is shown. Figure 8 The cross-sectional view in the middle is along the orthogonal to Figure 1 The plane is intercepted by line 7-7 in the middle. For example... Figure 1 As shown, the housing includes an elongated recess 122 on opposite sides of the housing. The recess may extend in a direction from the second inlet to the second outlet. The recess may be positioned at an intermediate location between the first inlet and the first outlet along the circumference of the housing, such as... Figure 8As shown in the diagram. For example, the indentation may be on opposite sides of the housing. Alternatively, the indentation may be in another location and / or more than two indentations may be contained within the housing. The indentation may reduce the distance or spatial clearance between the inner surface of the housing and the core. For example, in a location away from the indentation, the core may be positioned at a distance 434 from the inner surface of the housing (e.g., Figure 5 and Figure 8 (as shown in the image), and at the dent, a distance of 600 mm from the inner surface of the housing (e.g.) Figure 7 and 8 (As shown in the image).

[0046] The reduced distance between the housing and the core in the indentations helps force the first fluid from the first inlet toward and out of the first outlet. These indentations reduce the volume of the first fluid flowing between the first inlets to compress the first fluid and help force it toward the first outlet.

[0047] Figure 9 Show along Figure 1 Another cross-sectional view of the transmission device shown in line 7-7. In the illustrated embodiment, the flexible diaphragm intersects with the inner surface of a housing having an arcuate junction. For example, instead of having corners or junctions between straight lines at the junctions between the inner surfaces of the flexible diaphragm and the inner surfaces of the housing, and at the junctions between the outer surfaces of the flexible diaphragm and the inner surfaces of the housing, the flexible diaphragm and / or housing may form rounded corners at one or both of these junctions. The flexible diaphragm and / or housing may have inner rounded corners 726 and outer rounded corners 728 on opposite sides of the junction between the flexible diaphragm and the housing. These rounded corners may be arcuate junctions, which increase the flexibility of the diaphragm (compared to junctions without arcuate edges or rounded corners). The inner rounded corners may have a smaller radius of curvature than the outer rounded corners, such as... Figure 9 As shown in the image.

[0048] Figure 10This is a perspective view of the core of a delivery device according to an embodiment. Each unit cell of the core has one or more curved sidewalls. The inner surface 800 of one or more sidewalls defines at least a portion of an internal passageway extending within and through the respective unit cell. The outer surface 802 of one or more sidewalls defines at least a portion of an external passageway in an intermediate space between the unit cells. The core has a height extending from a bottom end 810 to a top end 812 (opposite to the bottom end). In the illustrated embodiment, the core has a generally cylindrical shape to conform to the interior of a housing. For example, the core has a circumferential outer side 814 extending from the top end to the bottom end. The surface along the outer side has grooves and corrugations attributable to the curved sidewalls of the unit cells. The internal passageway of the unit cells allows a first fluid to flow generally along the vertical height of the core, for example, downward from the top end and outward through the bottom end. The external passageway allows a second fluid to flow laterally, radially, and circumferentially (and vertically). For example, the second fluid can enter the external passageway through the cylindrical outer side of the core, such as... Figure 3 and 8 As shown in the image.

[0049] The unit cells in the core are arranged in an array. In an embodiment, the cells are disposed in multiple rows 816 stacked along the height of the core. The illustrated embodiment shows at least a portion of four rows 816a, 816b, 816c, 816d of unit cells. Each row contains multiple unit cells spaced apart from each other. The unit cells in a row may be staggered or offset from the unit cells in the row above or below. For example, a single unit cell may be disposed at least partially above multiple unit cells in the row. Staggering the positions of the unit cells promotes fluid-sidewall contact interaction by forcing a first fluid to meander through internal pathways rather than falling substantially freely through the core. Heat transfer and / or material transfer occur via fluid-sidewall interaction. In an embodiment, a given unit cell in an intermediate row (e.g., 816b, 816c) is interconnected to unit cells in the rows above and below. Optionally, the unit cells may not be directly fluidly connected to other unit cells in the same row.

[0050] Apart from the peripheral units along the outer sides, which are deformed to maintain the specified size and shape of the core, the unit units of the core may have the same size and shape as each other. The sidewalls of the unit units along the outer sides of the core may have a flatter (e.g., smaller) curvature relative to the sidewalls along the inner unit units. The sidewalls at the outer sides close the internal passageways to maintain mechanical separation between the first fluid and the second fluid.

[0051] Figure 10 The core shown in the article and Figure 8The core shown has fewer unit cells compared to those in an array, for example, to illustrate that the number and size of unit cells can be selected based on application-specific parameters, such as the amount of heat transfer, fluid flow resistance, fluid pressure drop, etc. According to at least one embodiment, the core is formed to have a relatively large unit cell size to reduce flow resistance and pressure drop and increase manufacturing efficiency (e.g., less material and printing), while providing sufficient fluid-sidewall interaction to achieve the desired transfer performance.

[0052] The sidewalls of the unit cell define a plurality of orifices 804, which represent portions of the internal passageway of the unit cell. For example, a first fluid can enter a corresponding unit cell through one of the orifices and exit the unit cell through another of the orifices. In an embodiment, the orifices of the unit cell are connected to other unit cells to fluidly connect the internal passageway through the core. Each orifice of the unit cell is fluidly connected to a different unit cell, such that the three orifices of the first unit cell are connected to a second, third, and fourth unit cell, respectively. The sidewalls have edges 806 extending around the orifices of the unit. The edges of the different unit cells are connected to each other to interconnect the internal passageways and seal the internal passageways from the external passageways.

[0053] In embodiments, the edges of the connecting unit cells are integrally joined to define seamless junctions between the unit cells. For example, the core may be a single, integral structure, wherein the unit cells are interconnected at seamless junctions. The material composition of the core may be selected based on application-specific factors. For example, materials with good thermal conductivity, such as one or more metallic materials, may be used for heat exchange applications in transfer devices. Other types of materials, such as polymeric materials, ceramic materials, or composite materials, may be used to form the core for filtration applications, wherein at least one component of a first or second fluid is transferred to and / or through the sidewalls of the unit cells.

[0054] According to at least one embodiment, the core is produced via additive manufacturing. The core is formed by sequentially depositing layers of building material, at least partially on top of each other, in the building direction. Figure 10 The structure shown is formed as described. The build-up material can be powder deposited in a bed and then selectively heated to provide a specified location, size, and shape for each layer according to a design document. Alternatively, the build-up material can be filaments heated and selectively deposited by a movable effector head to provide a specified location, size, and shape for each layer according to a design document. In the illustrated embodiment, the core can be additively manufactured in the upward build direction 808. For example, a bottom end 810 can be initially formed, and subsequent layers are stacked on top of each other until the top end 812 is finally formed to complete the build-up process.

[0055] Figure 11 for Figure 10 The image shows a cross-sectional view of the core. Figure 11 The cross-sectional view in the middle is along with Figure 10 The plane at the top end of the core is orthogonally cut off by a plane, and the cross-sectional plane can bisect the core. Figure 11 Shows a bisected view of two complete unit cells and multiple partial unit cells indicated by dashed circles. Figure 11 Four apertures 804 are shown, defined by the sidewalls of each of the complete unit cells. For example, two apertures are cut off at the upper right and lower left regions of the cell, and two more apertures are shown at the upper left and lower right regions extending the depth into the core. In this embodiment, the unit cell has a total of six apertures, and due to the cross-section, from Figure 11 The other two orifices are omitted. The six orifices provide flow channels to connect each unit cell to six other unit cells. In an alternative embodiment, the unit cell may have a different number of orifices.

[0056] like Figure 10 and 11 As shown, the complete unit cell has a spherical shape. For example, portions of the sidewalls of each unit cell between the apertures have a convex curvature relative to the center of the unit cell to define the sphere. Optionally, the unit cell may be at least slightly elongated to define an ellipse or oval shape.

[0057] The unit cells in adjacent rows are staggered, causing the internal pathways to extend at an angle relative to the row plane and the vertical height of the core, which facilitates fluid and sidewall interaction. A line 21 extending from the center point 822 of the first unit cell to the center point 822 of the second unit cell connected to the first unit cell defines an angle 824 of not less than 30 degrees and not more than 60 degrees relative to the row plane (e.g., a horizontal plane). The angle may be between 35 degrees and 45 degrees, for example, between 40 degrees and 42 degrees, depending on a more preferred range. These angles can be selected to ensure sufficient printability and print quality of the additively manufactured core, and also provide efficient cell row packaging.

[0058] The dimensions of the internal and external passages vary along their length. Along the internal passage, an orifice defines a narrowest or restrictive flow dimension 818. The orifice of a unit cell may be larger than the narrowest or restrictive flow dimension 820 in the external passage. The internal passage may occupy more space within the core compared to the external passage. The flow dimension and passage size settings may vary based on the type of fluid flowing through the passage and / or the desired transfer occurring between fluids passing through the sidewalls. In an embodiment, the first fluid through the internal passage is a hot gas, and the second fluid through the external passage is a cooler coolant, such as water. In an alternative embodiment, the size of the unit cell and / or the spacing between unit cells may be varied such that the restrictive flow dimension in the external passage is larger than the restrictive flow dimension in the internal passage and / or the external passage occupies more space within the core compared to the internal passage.

[0059] The unit cell includes at least some conical features or cones 826 disposed in the orifices of the respective unit cell. The cones 826 project toward the center point of the unit cell. The cone has a apex 830 located between the center point of the unit and a portion of the sidewall at the base of the cone. The cone 826 is hollow, such that a portion of the cone along the outer surface of the sidewall defines a recess 828. Several recesses of the cone are shown in... Figure 10 In the perspective view.

[0060] The cone is located at the base of the curved unit cell. For example, the cone may be positioned relative to the direction of gravity at the lowest portion of the unit cell. In an embodiment, the cone is positioned along the centerline of the unit cell. When the unit cell is curved, such as spherical, forming a cone at the base or bottom of the unit cell enhances the printability of the core without requiring a support structure. For example, as... Figure 11 As shown, the unit cell's base is unsupported. Forming inflection points along the sidewalls at the base avoids the problems associated with printing relatively flat surfaces and / or the lowest points of curves without any supports. The cone allows the unit cell to maintain a generally spherical shape without printing island-like structures to support the build material during the manufacturing process. The cone also prevents fluid from accumulating within the unit cell's sidewalls. For example, if it is a liquid, the initial fluid will flow from the cone toward the orifice surrounding the cone.

[0061] In an embodiment, the sidewall of the unit cell further includes a second conical feature or cone 832 along the top portion of the unit cell. The second cone is spaced apart from the first cone and positioned relative to the first cone among different sets of orifices in the unit cell. The first cone is referred to herein as the lower cone 830, and the second cone as the upper cone 832. The upper cone is hollow and defines a recess 834. The upper cone projects relative to the core in the same direction as the lower cone. For example, both cones project toward the top end of the core. The recess of the upper cone is defined along the inner surface of the sidewall. Optionally, the upper cone may be collinear with the lower cone. The upper cone may be included to improve the printability of the unit cell in the core, similar to including the lower cone. The presence of the upper cone eliminates a relatively flat area at the top of a curved unit cell, which could be difficult to print reliably without an underlay support.

[0062] Figure 12 Show along Figure 11 The first cross-sectional view of the core of line 12-12 shown in the figure. Figure 13 Explanation along Figure 11 The second cross-sectional view of the core of line 13-13 shown in the figure. Figure 14 Explanation along Figure 11 The third cross-sectional view of the core of line 14-14 shown in the figure. Figure 15 Explanation along Figure 11 The fourth cross-sectional view of the core of line 15-15 shown in the figure. Figures 12 to 15 The diagram in the image represents Figure 10 The image shows a top-to-bottom view of a core segmented along different parallel planes. This is part of the additive manufacturing process for the core, from bottom to top. Figures 12 to 15 The sections shown indicate different time-sequence stages of the build process. The core is formed using relatively thin sidewalls to improve printing efficiency by limiting the amount of material to be printed, and to provide relatively large pathways inside and outside the cell to limit fluid flow resistance and pressure drop.

[0063] Figure 12 The core section shown comprises a circle 900 at its radial center and six semicircles 902 surrounding the central circle. These shapes represent portions of the seven unit cells in the first row of the core. Three small circular openings 904 are arranged in a triangle around the central circle. The small openings represent the recessed portions of the lower cones of the unit cells in the upper row. The circular section 906 defining the sidewalls of the small openings is... Figure 11 The lower cone portion shown in the image.

[0064] Figure 13 The core sections shown include those placed in Figure 12The diagram shows three complete unit cells and three partially peripheral unit cells in the second row above the units in the first row. The unit cells in the second row are segmented by cutting lines 13-13. The three complete unit cells are spaced apart in a triangular arrangement. External pathways are defined in the space between the unit cells in the second row. In an embodiment, each of the complete unit cells is built on top of and individually connected (via the edge of the aperture) to the plurality of unit cells in the lower row. Each complete unit cell may be positioned above a portion of the three lower unit cells.

[0065] A portion 910 of the sidewall, positioned between multiple orifices, lies within the circular outline of each unit cell. This portion defines the base or bottom of the unit cell and includes a lower cone. Figure 13 In the unit cell, the visible sidewall portion has a generally triangular shape and is located between three orifices. The three orifices are spaced 120 degrees apart along the circumference of the unit cell. The lower cone is centrally positioned among the three orifices surrounding the triangular portion and is equidistant from the three orifices. Within each of the three visible orifices in the complete unit cell, fluid flows through them to connect to different unit cells in the row below. For example, the orifices connect each unit cell to three underlying unit cells, each unit cell extending at least partially above and overlapping the corresponding underlying unit cell. As the first fluid flows through the internal passage of the corresponding unit cell, the first fluid branches into the three connected units. Figure 13 It also displays the top of the upper cone of the centered unit.

[0066] Figure 14 The core segment shown comprises three complete unit cells and three partially peripheral unit cells in a third row, positioned on top of the units in the second row. The arrangement of the unit cells in the third row is the reverse of the arrangement of the unit cells in the second row (e.g., flipped relative to the arrangement of the unit cells in the second row). For example, similar to... Figure 13 , Figure 14 The three complete unit cells are arranged in a triangle, but the triangle is relative to... Figure 13 The triangular arrangement in the diagram is flipped 180 degrees. In one embodiment, the sidewall of the complete unit cell has three orifices that fluidly connect the respective unit cell to three different unit cells in the upper row. For example, unit 212a in the second row is fluidly connected to three units 212b, 212c, and 212d in the third row. The complete unit cell according to the illustrated embodiment comprises a total of six orifices, including three orifices connecting to units in the lower row and three orifices connecting to units in the upper row. First fluid can enter the unit cell through one or more of the orifices and exit the unit cell through one or more of the other orifices.

[0067] Figure 15 This is a plan view showing the top end of the core. The top of the core is contained within... Figure 14 The cross-section shows multiple incomplete unit cells in the fourth row of the core above the unit cells in the third row. Figure 15 The unit shown in the document has the same characteristics as Figure 12 The arrangement and shape of the unit cells in the first row shown are similar. In an embodiment, each row of unit cells in the core has one of three unit arrangements, and the rows alternate in a repeating pattern among the three unit arrangements along the height of the core. In an alternative embodiment, the unit cells may be arranged in a different number of repeating configurations.

[0068] Figure 16 According to the embodiment, an enlarged area is provided to show the upper cone 832 and the lower cone 826. Figure 11 The image shows a cross-sectional view of the core. In the illustrated embodiment, the lower cone is larger than the upper cone. For example, the base of the lower cone is wider than the base of the upper cone. The lower cone also has a greater height from the base to the apex compared to the upper cone. The recess 828 of the lower cone has a larger volume compared to the recess 834 of the upper cone. The lower cone may be larger than the upper cone due to printability considerations. In alternative embodiments, the upper and lower cones may be the same size, or the upper cone may be larger than the lower cone.

[0069] The core can be manufactured with thin walls throughout. For example, the wall thickness of the sidewalls can be less than 3 mm, even in the thickest sections. In embodiments, the sidewall thickness is between 0.3 mm and 1.5 mm (inclusive of the endpoints). The diameter of the orifice can be significantly larger than the wall thickness, for example, at least 3 mm. In embodiments, the orifice can be at least ten times the wall thickness, for example, up to 15 mm or more. Optionally, the thickness of the sidewalls can vary within this relatively narrow range. For example, the sidewalls along the lower cone can be thicker than the sections of the sidewalls extending from the lower cone. Optionally, the sidewalls along the upper cone can also be thicker than the sections of the sidewalls extending from the upper cone. The lower cone wall thickness can be thicker than the upper cone wall thickness to support the larger size and larger inflection point of the lower cone relative to the upper cone.

[0070] Thin walls allow the core to have relatively large unit cells and orifices. For example, for a complete unit cell that does not deform along the periphery of the core, the unit cell size can be between 10 mm and 30 mm. For a spherical unit cell, the unit cell size refers to the inner diameter of the sidewall. In a non-limiting example, the unit cell size is approximately 20 mm. The unit cell size can be selected based on application-specific factors such as fluid flow rate and delivery properties, rather than printability considerations. For example, known cores with repeating geometries have significantly smaller unit cell sizes to avoid the use of internal support structures within the core, or alternatively have larger unit cell sizes but include internal support structures. Known cores do not contain large unit cell sizes without internal support structures.

[0071] Figure 17 A flowchart illustrating an example of a method 1000 for creating a transfer device or a component thereof. The method can be used to create one or more embodiments of the transfer device shown and / or described herein. The method can be performed by an additive manufacturing system, such as a 3D printing system that automatically prints the transfer device using input files such as STL, OBJ, AMF, 3MF, etc. At step 1002, a material layer is deposited onto a work surface. For example, a first material layer for forming the transfer device may be printed from one or more filaments onto the work surface. At step 1004, an additional material layer is deposited on the underlying material layer. This additional layer may be at least partially printed onto the material layer deposited prior to this additional layer. At step 1006, a decision is made regarding whether to complete the manufacturing of the transfer device. If the additional layer is to be deposited to complete the formation of the entire transfer device, the flow of the method may return to step 1004, such that one or more additional layers may be deposited as described above (until the creation of the transfer device is complete). Layers may be deposited sequentially, at least partially on top of each other, to form the shapes of a shell, a flexible diaphragm, and a core. The phrase "at least partially" means that the entire layer or less can be printed on top of the underlying layer. If the creation of the transfer device is complete, the process can proceed to step 1008. In step 1008, the transfer device is removed from the work surface. The transfer device can then be used to transfer energy and / or components between fluids, as described above.

[0072] Optionally, method 1000 can be used to form a component of the transfer device, such as a core, without forming at least one other component of the transfer device. For example, the core can be additively manufactured by sequentially depositing layers of material, at least partially on top of each other, in the build direction. Additive manufacturing can be performed by a 3D printing system according to instructions in an input design file to produce the core according to the embodiments described herein. For example, the method can be executed to print... Figures 10 to 16 The core shown in the image.

[0073] Suitable processes include, for example, laser powder bed fusion, electron beam powder bed fusion, directed energy deposition (DED), and binder jetting. Laser powder bed fusion involves depositing powder layers on a build plate and selectively fusion power using a ytterbium fiber laser that scans a CAD pattern. Laser powder bed fusion may include selective laser melting or sintering. DED can be used to print at least portions of a core and / or a transfer device, the DED being printed at extremely high rates. For example, DED can be used to print a housing of a transfer device, which can then be fused directly to a flexible diaphragm attached to the core. Binder jetting creates parts by inserting a metal powder and polymer binder that bonds particles and layers together without the use of laser heating. The core material can be selected at least in part based on the proposed additive manufacturing method. For example, a binder jetting material comprising a binder and metal (or ceramic, or cermet) can be prepared into a green form (e.g., a shape prior to sintering). The green form can be in its final shape or can be shaped such that the sintered form is the final shape.

[0074] The core of the delivery device according to embodiments described herein is a three-dimensional structure in which interconnected unit webs are arranged in a regularly repeating pattern. The properties and characteristics of the core can be selected based on specific application parameters and desired functionality. For example, the shape of individual (and repeating) units within the structure can be selected to increase structural strength, thermal conductivity, flow volume or delivery rate through the core, surface area for fluid-film interactions, etc. Optionally, the angle or slope of the sidewalls, the thickness of the sidewalls, the material composition of the sidewalls, the size of the sidewalls, and other properties of the sidewalls, such as density, relative density, porosity, etc., can be selected to obtain desired strength, conductivity, surface area, density, heat dissipation capacity, etc. Relative density represents the density of the material divided by the density of the core. Porosity represents a measurement of the amount of void material (e.g., air) occupying the volume.

[0075] Properties can be uniform throughout the core. Alternatively, they can vary along the core's height, radial thickness, etc., so that one or more properties in one region of the core can differ from those in another region. The unit cells can vary in shape, size, thickness, or spacing throughout the core structure to improve the heat exchanger's performance characteristics. For example, unit cell size (e.g., diameter), orifice diameter, spacing between unit cells, the ratio between the sizes of internal and external passages, and / or sidewall thickness can be selectively varied to control fluid flow, heat transfer, material transfer (e.g., filtration) to and / or through the sidewalls, etc. Changing flow resistance can help diffuse fluid to areas that naturally receive less fluid flow compared to other areas. In a non-limiting example, unit cells closer to the radial center of the core can be smaller or closer together than unit cells closer to the periphery or outer sides of the core. Smaller sizes can increase flow resistance through more centrally located internal and / or external passages, which can force more fluid towards the periphery.

[0076] The core may be formed of at least one plastic, ceramic, and / or metallic material. Plastic materials may include or represent epoxy resins, vinyl esters, polyester thermosetting polymers (e.g., polyethylene terephthalate (PET)), polypropylene, etc. Ceramic materials may include or represent silica, alumina, silicon nitride, etc. Metallic materials may include or represent aluminum alloys, titanium alloys, cobalt-chromium alloys, stainless steel, nickel alloys, etc. The core may be a composite comprising a mixture of multiple materials, such as a plastic having ceramic elements, a ceramic having metal elements (referred to as a cermet composite), and / or a plastic having metal elements. Optionally, the core may represent a reinforcing composite, such as a fiber-reinforced plastic. Fiber-reinforced plastics may contain embedded fibers within a matrix layer of the plastic. The fibers may be carbon fibers, glass fibers, aramid fibers (e.g., ... Basalt fibers, naturally occurring bio-fibers (e.g., bamboo), etc. In other embodiments, the reinforcing composite can be reinforced with materials of other shapes than fibers, such as powders or strips. The reinforcing member can be embedded within any of the plastics listed above. The metal-ceramic composite can be composed of any of the ceramics and metals listed above. For the additive printing process, the material can be provided in particulate form, such as powder, and the printing system selectively fuses the particulates together to form each layer of the solid building block.

[0077] The additive manufacturing system and / or post-printing instrumentation can be controlled to apply specific surface coatings to the core that affect how the core interacts with the fluid flowing through it. For example, a rougher surface coating, relative to a smoother surface coating, can increase flow resistance, increase heat transfer, and / or increase material transfer through the sidewalls. Optionally, the surface coating can vary along the core to selectively control fluid flow and / or transfer throughout the core.

[0078] In one or more embodiments, a heat transfer device includes an outer housing, an inner heat transfer core, and a flexible diaphragm connected to and extending from the core to an inner surface of the outer housing. The housing includes: a first inlet for receiving a first fluid; a second inlet for receiving a second fluid; a first outlet through which the first fluid is guided out of the housing; and a second outlet through which the second fluid is guided out of the housing. The core forms a first inner passage and a second inner passage that are separated from each other. The first inner passage fluidly couples the first inlet to the first outlet, and the second inner passage fluidly couples the second inlet to the second outlet. The flexible diaphragm forms a flexible transition between each of the first and second inlets of the housing and the core. The flexible diaphragm also forms a seal to prevent the first fluid flowing through the first inner passage from flowing into the second inner passage of the core.

[0079] The flexible diaphragm may have a curved conical shape extending from the shell to the core. The flexible diaphragm may extend inward from the inner surface of the shell to the core. The flexible diaphragm may intersect with the inner surface of the shell and may include inner and outer fillets on opposite sides of the intersection between the flexible diaphragm and the shell. The inner fillet may have a smaller radius of curvature than the outer fillet.

[0080] The shell, core, and flexible diaphragm can be a single, integral unit. The flexible diaphragm can be thinner than the outer shell. The inner surface of the flexible diaphragm facing the core can form an angle of less than 45 degrees relative to the inner surface of the outer shell. The outer surface of the flexible diaphragm facing away from the core can form an angle of greater than 45 degrees relative to the inner surface of the outer shell.

[0081] The core can transfer heat between a first fluid flowing in a first inner passage and a second fluid flowing in a second inner passage without mixing the two fluids. The first inner passage of the core can extend between the flexible diaphragm and the inner surface of the outer shell.

[0082] In one or more embodiments, a heat transfer device comprises an integral structure consisting of an outer housing, an inner heat transfer core, and a flexible diaphragm connected to and extending from the core to an inner surface of the outer housing. The core has a first inner passage and a second inner passage separate from the first inner passage. The core can transfer heat between a first fluid flowing in the first inner passage and a second fluid flowing in the second inner passage without mixing the two fluids. The flexible diaphragm forms a flexible transition between the core and each of the first and second inlets of the housing. The flexible diaphragm also forms a seal to prevent the first fluid from flowing into the second inner passage of the core.

[0083] The flexible diaphragm may have a curved conical shape extending from the shell to the core. The flexible diaphragm may extend inward from the inner surface of the shell to the core. The flexible diaphragm may intersect with the inner surface of the shell and may include inner and outer fillets on opposite sides of the intersection between the flexible diaphragm and the shell. The inner fillet may have a smaller radius of curvature than the outer fillet.

[0084] The shell, core, and flexible diaphragm can be a single unit. The flexible diaphragm can be thinner than the outer shell. The inner surface of the flexible diaphragm facing the core can form an angle of less than 45 degrees with the inner surface of the outer shell, and the outer surface of the flexible diaphragm facing away from the core can form an angle of greater than 45 degrees with the inner surface of the outer shell.

[0085] In one or more embodiments, a method includes additively manufacturing a heat transfer device by sequentially depositing layers of material on top of each other to form a body having an outer shell, an inner heat transfer core, and a flexible diaphragm, the flexible diaphragm being connected to the core and extending to an inner surface of the outer shell. The shell formed by the sequential deposition of layers has: a first inlet configured to receive a first fluid; a second inlet configured to receive a second fluid; a first outlet through which the first fluid is guided out of the shell; and a second outlet through which the second fluid is guided out of the shell. The flexible diaphragm formed by the sequential deposition of layers serves as a flexible transition between the core and each of the first and second inlets of the shell. The flexible diaphragm formed by the sequential deposition of layers also serves as a seal preventing the first fluid from flowing into a second internal passageway of the core.

[0086] Unless the context clearly indicates otherwise, the singular forms “a / an” and “the” include plural references. “Optional” or “optionally” means that the event or situation subsequently described may or may not occur, and this specification may include examples of events occurring and examples of events not occurring. As used herein throughout the specification and claims, approximate language may be used to modify any quantitative representation that may be varied without causing a change in the fundamental function it may involve. Thus, a value modified by one or more terms such as “about,” “substantially,” and “approximately” may not be limited to the specified precise value. In at least some instances, approximate language may correspond to the precision of the instrument used to measure the value. Scope limitations may be combined and / or interchanged herein and throughout the specification and claims, and such scopes are identifiable and include all subscopes included therein unless otherwise indicated by context or language.

[0087] This written description uses examples to disclose embodiments containing the best mode and to enable those skilled in the art to practice the said embodiments, including making and using any apparatus or system and performing any incorporated methods. The claims define the patentable scope of this disclosure and include other examples known to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements identical to the literal language of the appended claims, or if they contain equivalent structural elements that are not substantially different from the literal language of the claims.

Claims

1. A heat transfer device, comprising: The system comprises an outer shell, an inner heat transfer core, and a flexible diaphragm disposed inside the outer shell, the flexible diaphragm being connected to the inner heat transfer core and extending to the inner surface of the outer shell. The outer housing comprises: The first inlet is configured to receive the first fluid; The second inlet is configured to receive the second fluid; A first outlet through which the first fluid is guided out of the outer casing; The second outlet is through which the second fluid is guided out of the outer casing. The internal heat transfer core forms a first internal passage and a second internal passage that are separate from each other. The first internal passage couples the first inlet to the first outlet fluid, and the second internal passage couples the second inlet to the second outlet fluid. The flexible diaphragm forms a flexible transition between each of the first and second inlets of the outer housing and the internal heat transfer core, and the flexible diaphragm also forms a seal to prevent the first fluid flowing through the first internal passage from flowing into the second internal passage of the internal heat transfer core.

2. The device according to claim 1, wherein the flexible diaphragm has a curved conical shape from the outer housing to the inner heat transfer core.

3. The device according to claim 1, wherein the flexible diaphragm extends inward from the inner surface of the outer housing to the inner heat transfer core.

4. The device according to claim 1, wherein the flexible diaphragm intersects with the inner surface of the outer housing, and includes inner and outer rounded corners on opposite sides of the junction between the flexible diaphragm and the outer housing.

5. The device according to claim 4, wherein the inner fillet has a smaller radius of curvature compared to the outer fillet.

6. The device according to claim 1, wherein the outer housing, the inner heat transfer core, and the flexible diaphragm are a single unit.

7. The device according to claim 1, wherein the flexible diaphragm is thinner than the outer housing.

8. The device according to claim 1, wherein the inner surface of the flexible diaphragm facing the internal heat transfer core forms an angle of less than forty-five degrees with the inner surface of the outer housing.

9. The device according to claim 1, wherein the outer surface of the flexible diaphragm facing away from the internal heat transfer core forms an angle greater than forty-five degrees with the inner surface of the outer housing.

10. The device of claim 1, wherein the internal heat transfer core is configured to transfer heat energy between the first fluid flowing in the first internal passage and the second fluid flowing in the second internal passage without mixing the first fluid and the second fluid.

11. The device of claim 10, wherein the first internal passage of the internal heat transfer core extends between the flexible diaphragm and the inner surface of the outer housing.

12. A heat transfer device, comprising: The assembly comprises an outer shell, an inner heat transfer core, and a flexible diaphragm disposed inside the outer shell, the flexible diaphragm being connected to the inner heat transfer core and extending to the inner surface of the outer shell. The internal heat transfer core has a first internal passage and a second internal passage separate from the first internal passage, and the internal heat transfer core is configured to transfer heat energy between a first fluid flowing through the first internal passage and a second fluid flowing through the second internal passage without mixing the first fluid and the second fluid. The flexible diaphragm forms a flexible transition between each of the first and second inlets of the outer housing and the inner heat transfer core, and the flexible diaphragm also forms a seal to prevent the first fluid from flowing into the second inner passage of the inner heat transfer core.

13. The device of claim 12, wherein the flexible diaphragm has a curved conical shape extending from the outer housing to the inner heat transfer core.

14. The device of claim 12, wherein the flexible diaphragm extends inward from the inner surface of the outer housing to the inner heat transfer core.

15. The device of claim 12, wherein the flexible diaphragm intersects with the inner surface of the outer housing, and includes inner and outer rounded corners on opposite sides of the intersection between the flexible diaphragm and the outer housing.

16. The device of claim 15, wherein the inner fillet has a smaller radius of curvature than the outer fillet.

17. The device according to claim 12, wherein the outer housing, the inner heat transfer core, and the flexible diaphragm are a single unit.

18. The device of claim 12, wherein the flexible diaphragm is thinner than the outer housing.

19. The device of claim 12, wherein the inner surface of the flexible diaphragm facing the inner heat transfer core forms an angle of less than 45 degrees with the inner surface of the outer housing, and the outer surface of the flexible diaphragm facing away from the inner heat transfer core forms an angle of greater than 45 degrees with the inner surface of the outer housing.

20. A method comprising: A heat transfer device is additively manufactured by sequentially depositing material layers on top of each other to form a body having an outer shell, an inner heat transfer core, and a flexible diaphragm disposed inside the outer shell, the flexible diaphragm being connected from the inner heat transfer core and extending to the inner surface of the outer shell, the outer shell being formed by the sequential deposition of the layers having: a first inlet configured to receive a first fluid; The second inlet is configured to receive the second fluid; A first outlet through which the first fluid is guided out of the outer casing; And a second outlet, through which the second fluid is guided out of the outer housing, wherein the internal heat transfer core forms a first internal passage and a second internal passage separated from each other, the first internal passage coupling the first inlet to the first outlet fluid, and the second internal passage coupling the second inlet to the second outlet fluid, such that the first fluid flows through the first internal passage and the second fluid flows through the second internal passage; wherein the layers are sequentially deposited to form a flexible diaphragm as a flexible transition between each of the first and second inlets of the outer housing and the internal heat transfer core, and the layers are sequentially deposited to form a flexible diaphragm as a seal to prevent the first fluid from flowing into the second internal passage of the internal heat transfer core.

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