METHOD FOR MANUFACTURING A HEAT EXCHANGER

Description

BACKGROUND 1. Field

[0001] The present disclosure relates to heat exchangers, more specifically to heat exchangers having multiple channels.2. Description of Related Art

[0002] In certain heat exchanger systems, two different fluids can be used. One fluid can cool and / or heat the other fluid. Existing structures have traditionally had limited complexity in their design, and thus have not fully maximized thermal efficiency.

[0003] Such conventional methods and systems have generally been considered satisfactory for their intended purpose. However, there is still a need in the art for improved heat exchangers. The present disclosure provides a solution for this need.

[0004] JP 2015059715 relates to a motor cooler and a method of manufacturing the motor cooler.SUMMARY

[0005] A method of forming a heat exchanger is provided as claimed in claim 1.

[0006] In certain embodiments, forming the body can include forming the body from metal powder. Forming the body includes laser sintering metal powder.

[0007] These and other features of the systems and methods of the subject disclosure will become more readily apparent to those skilled in the art from the following detailed description taken in conjunction with the drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Fig. 1 is a perspective view of a flow volume (inverse of structure) of an embodiment of a heat exchanger not according to the invention showing a first channel wrapped around a second channel; Fig. 2A is a side view of the embodiment of Fig. 1; Fig. 2B is a sectional view of the embodiment of Fig. 1; Fig. 3 is a side, partially cross-sectional view of an embodiment of a heat exchanger which can be manufactured with the method of the invention, showing a first flow channel wrapped inside a second flow channel, the second flow channel shown in cross-section; Fig. 4A is a plan view of the embodiment of Fig. 3; and Fig. 4B is a sectional view of the embodiment of Fig. 3. DETAILED DESCRIPTION

[0009] Reference will now be made to the drawings wherein like reference numerals identify similar structural features or aspects of the subject disclosure. For purposes of explanation and illustration, and not limitation, an illustrative view of an embodiment of a heat exchanger is shown in Fig. 1 and is designated generally by reference character 100. Other embodiments and / or aspects are shown in Figs. 2A-4. The systems and methods described herein can be used to enhance thermal efficiency of heat exchangers.

[0010] Referring to Figs. 1, 2A, and 2B, a heat exchanger 100 can include a monolithically formed body 102 defining at least two channels configured to allow fluid to flow therethrough. At least one of the at least two channels at least partially wraps around or within at least one other of the at least two channels. In certain embodiments, the at least two channels can include at least a first channel 101 and a second channel 103. Any other suitable number of channels (e.g., third, further, fifth, etc.) is contemplated herein. The body 102 is not shown in Figs. 1 and 2A because the first and second channels 101, 103 are shown in inverse for clarity. The body 102a can be any suitable shape or size, and made for any suitable application.

[0011] At least the first channel 101 can be at least partially wound around or within the second channel 103, or at least the second channel 103 can be at least partially wound around or within the first channel 101, or at least the first channel 101 and the second channel 013 can be at least partially wound around each other. For example, the first channel 101 can be helically or non-helically wound around the second channel 103, as shown, or vice versa. Any other type of winding is contemplated herein, and the first channel 101 need not be smooth. The first channel 101 and the second channel 103 are fluidly isolated from each other and / or can have any suitable shape (e.g., helical, non-helical, straight, etc.).

[0012] In certain embodiments, the first channel 101 can be wound around the second channel 103 outside of the second channel 103 as shown in Figs. 1-2B. Referring to Fig. 3 and 4, in certain embodiments, a heat exchanger 300 can include a body 302 that defines a first channel 301 that is wound within body 302 to form a second channel 303 such that fluid within the second channel 303 contacts an outer wall of the first channel 301.

[0013] The first channel 301 and the second channel 303 are fluidly isolated from each other. The first channel 301 can terminate into the body 302 as shown in Fig. 3 to create outlets 304, for example.

[0014] The second channel 103, 303 can be straight or any other suitable shape (e.g., curved). In certain embodiments, the second channel 103, 303 can be cylindrical in shape (e.g., have a circular cross-section). Any other suitable shape is contemplated herein.

[0015] The body 102, 302 can be formed of metal (e.g., Cu, Ni alloy, Al, Ti alloy) or any other suitable material. In certain embodiments, the body 102, 302 can be laser sintered.

[0016] A method of forming a heat exchanger includes monolithically forming a body 102, 302 to define at least two channels configured to allow fluid to flow therethrough, at least one of the at least two channels at least partially wrapping around or within at least one other of the at least two channels. Forming the body to define at least two channels includes defining a first channel 101, 301 and a second channel 103, 303 such that the first channel 101, 301 is at least partially wound around or within the second channel 103, 303. Forming the body 102, 302 can include forming the first channel 101, 301 such that the first channel 101, 301 is helically wound around the second channel 103, 303.

[0017] Forming the body 102 can include forming the first channel 101 such that the first channel 101 is wound around the second channel 103 outside of the second channel 103. Forming the body 302 can include forming the first channel 301 such that the first channel 301 is wound around the second channel 303 inside the second channel 303 such that fluid within the second channel 303 contacts an outer wall of the first channel 301.

[0018] Forming the body 102, 302 can include forming the second channel 103, 303 such that the second channel 103, 303 is straight. In certain embodiments, forming the body 102, 302 can include forming the second channel 103, 303 such that the second channel 103, 303 is cylindrical in shape.

[0019] In certain embodiments, forming the body 102, 302 can include forming the body 102, 302 from metal powder. Forming the body 102, 302 can include laser sintering metal powder.

[0020] Embodiments as described above can be used for cooling and / or heating applications. While embodiments are shown having two channels, any suitable number of fluidly isolated channels is contemplated herein (e.g., two helical first channels around a second channel to form a double helix). Flow can be passed through the first and second channels in a concurrent direction or a different direction. The first channel can be wrapped around the second channel as tightly (amount of winds per unit length of the second channel) as is suitable.

[0021] Additive manufacturing allows unique configurations that cannot be produced in current machining practices. Embodiments as described herein include internal passages that allow flow of two different fluids around each other.

Claims

1. A method of forming a heat exchanger (300), comprising monolithically forming a body (302) to define two channels (301,303) configured to allow fluid to flow therethrough, one (301) of the two channels (301,303) wrapping within the other of the two channels (303); wherein forming the body (302) to define two channels includes defining a first channel (301) and a second channel (303) such that the first channel (301) is wound within the second channel (303); and wherein the first channel (301) terminates into the body (302) at an opening defined by the body (302) to create outlets (304).

2. The method of claim 1, wherein forming the body (302) includes forming the first channel (301) such that the first channel (301) is helically or non-helically wound around the second channel (303).

3. The method of claim 1, wherein forming the body (302) includes forming the body (302) from metal powder, or wherein forming the body (302) includes laser sintering metal powder.