Additively manufactured heat exchanger

Abstract

The invention relates to a heat exchanger (1) for a fluidically separated heat exchange between a first fluid and a second fluid. An increased efficiency as well as a mechanical stability of the heat exchanger (1) are achieved in that the heat exchanger (1) has an additively manufactured heat exchanger block (2) with first flow channels (3) for the first fluid and second flow channels (5) for the second fluid as well as first fluid chambers (7) for the first fluid and second fluid chambers (8) for the second fluid, wherein at least one of the second flow channels (5) is guided through at least one of the first fluid chambers (7) to at least one of the second fluid chambers (8). The invention additionally relates to a system (100) comprising a feed device (101), a circuit (102), and such a heat exchanger (1) and to a tank system (200) comprising such a system (100).

Description

[0001] Additively manufactured heat exchanger

[0002] The present invention relates to an additively manufactured heat exchanger for fluidically separated heat transfer between a first fluid and a second fluid. The invention further relates to a system comprising such a heat exchanger. Furthermore, the invention relates to a tank system comprising such a system.

[0003] A heat exchanger is used for fluidically separated heat transfer between two fluids. For this purpose, the heat exchanger typically has a heat exchanger block through which the flow paths of the two fluids run fluidically separated from each other, so that heat transfer takes place between the fluids within the heat exchanger block. Typically, the heat exchanger block has spaced-apart tubular bodies for a first of the fluids, through which the flow path of the first fluid runs. The spaced-apart arrangement of the tubular bodies defines the flow path for the other fluid. To increase heat transfer, so-called corrugated fins or lamellae are typically arranged between the tubular bodies.To supply the tubular bodies with the first fluid, the heat exchanger generally also has chambers into which the tubular bodies open and which in turn are usually designed as a tube or a box. The heat exchanger can also have associated chambers for guiding the second fluid between the tubular bodies. Such a heat exchanger therefore usually comprises a large number of individual, separate components which are connected to one another. The connection of the individual components is usually materially bonded, for example by means of soldered joints. This leads to a complex and complicated production of such a heat exchanger. Furthermore, the transitions between the individual components, in particular between the chambers and the tubular bodies, form points that are susceptible to stresses of both thermal and mechanical origin.The present invention is concerned with the object of providing improved or at least alternative embodiments for a heat exchanger for fluidically separated heat transfer between two fluids, for a system with such a heat exchanger and for a tank system with such a system.

[0004] This object is achieved according to the invention by the subject matter of the independent claims. Advantageous embodiments are the subject matter of the dependent claims.

[0005] The present invention is therefore based on the fundamental idea of ​​additively manufacturing a heat exchanger block of a heat exchanger and forming flow channels for the first fluid and the second fluid in the heat exchanger block, so that the first fluid and the second fluid can transfer heat to one another within the heat exchanger block. The heat exchanger further comprises two associated chambers for each fluid, which supply the flow channels associated with the fluid with the fluid. The chambers of one of the fluids are arranged on the outside of the chambers of the other fluid, and the flow channels associated with the external chambers lead through the chambers of the other fluid to the associated chambers.The formation of flow channels in the additively manufactured heat exchanger block leads to increased heat transfer between the fluids and also allows for the formation of a larger number of flow channels for both fluids, thus in turn achieving increased heat transfer. Routing the flow channels of one of the fluids through the chambers of the other fluid to the corresponding chambers leads to heat transfer within the first chamber, thus further increasing heat transfer. Overall, this results in a significant increase in heat transfer between the fluids and thus a significant increase in the efficiency of the heat exchanger.Secondly, routing the flow channel through the chambers of the other fluid causes the flow channel through the chambers to act as a tie rod for the other chambers and / or for the other flow channels, resulting in significantly increased mechanical stabilization of the heat exchanger. The solution according to the invention thus achieves both a significant increase in efficiency and significant mechanical stabilization of the heat exchanger.

[0006] According to the inventive concept, the heat exchanger serves for the fluidically separated heat transfer between two fluids, which are also referred to below as the first fluid and the second fluid for easier differentiation. The heat exchanger has the additively manufactured heat exchanger block. The heat exchanger block has three mutually perpendicular directions, which are also referred to below as the block longitudinal direction, block transverse direction, and block height direction. Flow channels for the first fluid are formed in the heat exchanger block and extend in the block transverse direction; these flow channels are also referred to below as first flow channels. The first flow channels thus penetrate the heat exchanger block, with a flow path of the first fluid, also referred to below as the first flow path, leading through the first flow channels.The heat exchanger block also has flow channels for the second fluid that extend in the transverse direction of the block; these second flow channels are also referred to below as second flow channels. The second flow channels penetrate the heat exchanger block, with a flow path of the second fluid, also referred to below as the second flow path, leading through the second flow channels. The first flow path and the second flow path are fluidically separated from one another. The heat exchanger has two chambers for the first flow channels and thus the first fluid, which are also referred to below as first fluid chambers. The first fluid chambers are formed at transverse ends of the first flow channels that face away from one another in the transverse direction of the block and are fluidically connected to the first flow channels, such that the first flow path leads through the first fluid chambers.The heat exchanger further comprises two chambers for the second flow channels and thus for the second fluid, which are also referred to below as secondary fluid chambers. The secondary fluid chambers are arranged, in particular formed, in the transverse direction of the block on the sides of the primary fluid chambers facing away from the first flow channels. The secondary fluid chambers are fluidically connected to the second flow channels, so that the second flow path leads through the secondary fluid chambers. At least one of the second flow channels leads through at least one of the primary fluid chambers to the secondary fluid chamber adjacent to the primary fluid chamber in the transverse direction of the block.

[0007] The at least one second flow channel leading through the at least one first fluid chamber to the at least one second fluid chamber thus acts in the manner of a tie rod acting in the block transverse direction for the at least one first fluid chamber and / or for the first flow channels.

[0008] The respective second flow channel leading through the at least one first fluid chamber is expediently fluidically connected to the second fluid chamber adjacent to the first fluid chamber.

[0009] Preferably, the respective second flow channel leading through the at least one primary fluid chamber is directly connected to the secondary fluid chamber adjacent to the primary fluid chamber. This results in an improved effect of the tie rod and thus increased mechanical stability. Additive manufacturing is understood here to mean manufacturing in which material is applied layer by layer. In particular, and preferably, additive manufacturing is a three-dimensional printing process. Additive manufacturing can be carried out using plastics and / or metals, preferably metals. Additive manufacturing allows the implementation of geometries that are not feasible, or only feasible with extremely high expenditure, using conventional manufacturing methods such as casting and machining.Thus, it is particularly possible to form first and second flow channels directly adjacent to one another in the heat exchanger block, resulting in the increased heat transfer and thus efficiency described above.

[0010] As explained above, the chambers serve to supply the associated flow channels with the associated fluid. One of the fluid chambers can be used to supply the associated fluid to the associated flow channels, and the other fluid chamber can be used to collect the associated fluid from the associated flow channels.

[0011] As explained, the first flow channels and the second flow channels extend in the transverse direction of the block. This means that during operation, the two fluids flow through the flow channels along the transverse direction of the block.

[0012] Advantageous variants are those in which the first fluid and the second fluid flow in opposite directions through the flow channels, i.e., the heat exchanger is designed as a so-called "counterflow heat exchanger." This results in a pronounced heat transfer between the fluids.

[0013] Preferred embodiments are those in which the fluid chambers, i.e., the primary fluid chambers and the secondary fluid chamber, are also additively manufactured. Thus, the first flow channels can directly merge into the primary fluid chambers and / or the secondary fluid chambers can directly merge into the secondary fluid chambers. Likewise, the respective primary fluid chamber can directly merge into the secondary fluid chamber adjacent in the block direction. In addition to increased heat transfer, this results in increased mechanical cohesion and thus increased mechanical stability. At the same time, the described effect of the tie rods is enhanced, thus further increasing mechanical stability.

[0014] Preferably, at least one of the secondary fluid chambers, preferably the respective secondary fluid chamber, lies on the adjacent primary fluid chamber in the transverse direction of the block. Thus, the secondary fluid chamber acts mechanically directly on the primary fluid chamber, improving and increasing its effect as a tie rod. Furthermore, this results in direct heat transfer between the two fluids, even within the fluid chambers. This means that both an increase in mechanical stability and an increase in efficiency are achieved. Preferred embodiments are those in which at least one of the secondary fluid chambers, preferably the respective secondary fluid chamber, lies directly on the adjacent primary fluid chamber or directly merges into the adjacent primary fluid chamber.

[0015] Alternatively or additionally, a further increase in mechanical stability and efficiency can be achieved by having at least one of the second flow channels lead through both of the first fluid chambers to the second fluid chamber adjacent to the respective first fluid chamber in the transverse direction of the block. This results in the tie rod acting on both sides in the transverse direction of the block and in heat transfer between the two fluids in both first fluid chambers, so that the further increase in mechanical stability and efficiency described above is achieved. Embodiments are considered advantageous in which at least one of the second flow channels, preferably the respective second flow channel, opens into the respective second fluid chamber and is connected, preferably directly, to the respective second fluid chamber, in particular merges directly into the respective second fluid chamber.In addition to a more compact design of the heat exchanger, this leads to increased heat transfer and mechanical stability of the heat exchanger.

[0016] In preferred embodiments, several, preferably a plurality, particularly preferably the respective second flow channel, lead through both primary fluid chambers to the secondary fluid chamber adjacent to the respective primary fluid chambers in the transverse direction. This leads to a further increase in both mechanical stability and efficiency.

[0017] The first flow channels and the second flow channels can be arranged in any manner relative to each other in the heat exchanger block.

[0018] Preferably, first flow channels and second flow channels follow one another in the longitudinal direction of the block. This results in increased heat transfer between the two fluids and thus greater efficiency.

[0019] Alternatively or additionally, increased heat transfer between the two fluids can be achieved by having first flow channels and second flow channels following one another in the block height direction.

[0020] An increase in the effect of the tie rod is advantageously achieved by ensuring that the first fluid in the first flow channels has a higher pressure than the second fluid in the second flow channels. The heat exchanger is advantageously used to cool the first fluid. The heat exchanger therefore advantageously acts as an evaporator of the second fluid during operation, transferring heat to the second fluid and cooling the first fluid.

[0021] The fluids can be of any type.

[0022] The second fluid is, for example, a coolant or refrigerant, such as propane R290.

[0023] The first fluid may be a gas and / or a fuel. In particular, the first fluid may be hydrogen or a hydrogen-containing compound, such as ammonia and the like, as a fuel.

[0024] The heat exchanger is advantageously used in a system which also has a supply device and a circuit. During operation, the first fluid flows through the supply device, wherein the supply device serves to supply the first fluid, for example to a tank, for example of a consumer. During operation, the second fluid circulates in the circuit. This means that the first flow path leads through the supply device and through the heat exchanger, and the second flow path leads through the circuit and through the heat exchanger. This means that the first flow path of the first fluid leads through the first fluid chambers and the first flow channels, and the second flow path of the second fluid leads through the second fluid chambers and through the second flow channels, in order to achieve fluidically separated heat transfer between the two fluids during operation.

[0025] It is preferred if the system, in particular the supply device and / or the circuit and / or the heat exchanger, is / are designed such that the first fluid flows through the first flow channels at a higher pressure than the second fluid through the second flow channels.

[0026] Advantageously, the heat exchanger is an evaporator of the second fluid, so that the second fluid cools the first fluid.

[0027] The system can be part of a tank system for refueling at least one tank, for example, a consumer, in particular a motor vehicle, with a fuel. Preferably, the fuel is the first fluid, which is thus advantageously cooled during operation and supplied to the consumer by means of the supply device.

[0028] The tank system advantageously has at least one, preferably at least two, points for refueling a tank, in particular the consumer, which are also referred to below as refueling points. The heat exchanger is expediently arranged upstream of at least one of the refueling points, such that the fuel is cooled before refueling.

[0029] The fuel can be of any type.

[0030] In particular, the fuel and thus the first fluid is a gas, in particular hydrogen or a hydrogen-containing composition.

[0031] Further important features and advantages of the invention emerge from the subclaims, from the drawings and from the associated description of the figures based on the drawings.

[0032] It is understood that the features mentioned above and those to be explained below can be used not only in the combination specified in each case, but also in other combinations or on their own, without departing from the scope of the present invention.

[0033] Preferred embodiments of the invention are illustrated in the drawings and are explained in more detail in the following description, wherein the same reference numerals refer to the same or similar or functionally identical components.

[0034] They show, schematically

[0035] Fig. 1 is a highly simplified, circuit diagram-like representation with an additively manufactured heat exchanger in a tank system,

[0036] Fig. 2 a sectional view of the heat exchanger.

[0037] A heat exchanger 1, as shown by way of example in Figures 1 and 2, serves for the fluidically separated heat transfer between two fluids. In the exemplary embodiments shown, a first of the fluids is, purely by way of example, a fuel, for example hydrogen or a hydrogen-containing composition, and the other, second fluid is a refrigerant, for example propane R290. During operation, the first fluid, i.e. the fuel, is cooled in particular by means of the second fluid, i.e. the refrigerant. The heat exchanger 1 is designed and / or operated as an evaporator 10 of the second fluid, such that the second fluid cools the first fluid.

[0038] In the embodiment shown in Figure 1, the heat exchanger 1 is part of a system 100 having a supply device 101 by means of which the first fluid, in the embodiment shown the fuel, is supplied to a tank (not shown), for example of a consumer 300, which in the example shown is a motor vehicle 301. For this purpose, the supply device 101 can have a pump 103 which conveys the first fluid or the fuel from a reservoir (not shown) to the consumer 300. The system 100 further has a circuit 102 through which the second fluid and thus the refrigerant circulates during operation. The circuit 102 can have a compressor 104 which compresses the second fluid and thus the refrigerant during operation.

[0039] The system 100 can, as shown in Figure 1, be part of a tank system 200. The tank system 200 has at least one refueling point 201 for refueling a tank, in the illustrated embodiment, the consumer 300, with the fuel. Only one such refueling point 201 is shown in Figure 1 purely by way of example and for the sake of simplicity.

[0040] The heat exchanger 1 is additively manufactured. According to Figure 2, the heat exchanger 1 has a heat exchanger block 2 that is additively manufactured, for example, from a metal. The heat exchanger block 2 has a block longitudinal direction X, a block transverse direction Y, and a block height direction Z, which run perpendicular to one another. Flow channels 3 for the first fluid are formed in the heat exchanger block 2 and are also referred to below as first flow channels 3. The first flow channels 3 penetrate the heat exchanger block 2 and extend in the block transverse direction Y. A flow path 4 of the first fluid leads through the first flow channels 3 and is also referred to below as first flow path 4. Flow channels 5 for the second fluid are also formed in the heat exchanger block 2 and are also referred to below as second flow channels 5.The second flow channels 5 penetrate the heat exchanger block 2 and extend in the block transverse direction Y. A flow path 6 of the second fluid, which is also referred to below as the second flow path 6, leads through the second flow channels 5. The fluids are fluidically separated from one another and flow fluidically separated from one another through the heat exchanger 2. This means that the first flow path 4 and the second flow path 6 are fluidically separated from one another. The heat exchanger 1 also has two fluid chambers 7 for the first fluid and two fluid chambers 8 for the second fluid. The fluid chambers 7 of the first fluid are also referred to below as the first fluid chambers 7 and the fluid chambers 8 for the second fluid are also referred to as the second fluid chambers 8.The first fluid chambers 7 are formed at transverse ends 9 of the first flow channels 3 facing away from one another in the block transverse direction Y and are fluidically connected to the first flow channels 3, such that the first flow path 4 leads through the first fluid chambers 7. In the system, the first flow path 4 (see Figure 1) therefore leads through the feed device 101 and through the heat exchanger 1. In the exemplary embodiment shown, the first flow channels 3 open directly into the first fluid chambers 7. In the exemplary embodiment shown, the first fluid chambers 7 are also additively manufactured, with the first flow channels 3 merging directly into the first fluid chambers 7. The second fluid chambers 8 are arranged in the block transverse direction Y on the side of the first fluid chambers 7 facing away from the first flow channels 3. This means that a second fluid chamber 8 is arranged on the side of the respective first fluid chamber 7 facing away from the first flow channels 3 in the block transverse direction Y.In the exemplary embodiment shown, the respective second fluid chambers 8 directly follow the first fluid chambers 7 adjacent in the block transverse direction Y and lie directly on the first fluid chambers 7 adjacent in the block transverse direction Y. As can also be seen from Figure 2, the second fluid chambers 8 are fluidically connected to the second flow channels 5, so that the second flow path 6 leads through the second fluid chambers 8. In the system 100, the second flow path 6 therefore leads through the circuit 102 and through the heat exchanger 1. In the exemplary embodiment shown, the second flow channels 5 open directly into both second fluid chambers 8 and are directly connected to the second fluid chambers 8. In the exemplary embodiment shown, the second fluid chambers 8 are also additively manufactured, with the second flow channels 3 merging directly into the second fluid chambers 8.In addition, in the embodiment shown, the respective first fluid chamber 7 merges directly into the adjacent second fluid chamber 8 in the block transverse direction Y.

[0041] According to Figure 2, at least one of the second flow channels 5 leads through at least one of the first fluid chambers 7 to the second fluid chamber 8 adjacent to the first fluid chamber 7 in the block transverse direction Y. In the exemplary embodiment shown, and preferably, the respective second flow channel 5 leads through both first fluid chambers 7 to the second fluid chamber 8 adjacent to the respective first fluid chamber 7 in the block transverse direction Y. This thus results, on the one hand, in improved heat transfer between the first fluid and the second fluid, because heat transfer also takes place in the first fluid chambers 7. On the other hand, the routing of the at least one second flow channel 5 through the at least one first fluid chamber 7 has the effect of a tension rod acting in the block transverse direction Y, resulting in increased mechanical stability of the heat exchanger 1.

[0042] In the exemplary embodiments shown, and preferably, the first fluid, i.e., the fuel, flows through the heat exchanger 1, in particular through the first flow channels 3, at a higher pressure than the second fluid, i.e., the coolant, flows through the heat exchanger 1, in particular through the second flow channels 5. Thus, the above-described effect, similar to a tie rod, is increased. The system 100 and / or the heat exchanger 1 is configured accordingly.

[0043] As can be seen in Figure 2, in the illustrated embodiment, first flow channels 3 and second flow channels 5 follow one another in the block longitudinal direction X. Furthermore, in the illustrated embodiment, first flow channels 3 and second flow channels 5 follow one another in the block height direction Z (not visible).

[0044] As further indicated in Figure 2, in the exemplary embodiments shown, one of the first fluid chambers 7 serves to supply the first fluid into the first flow channels 3 and the other first fluid chamber 7 serves to collect the first fluid from the first flow channels 3. In the exemplary embodiment shown, one of the second fluid chambers 8 also serves to supply the second fluid to the second flow channels 5 and the other second fluid chamber 8 serves to collect the second fluid from the second flow channels 5. As can also be seen from Figure 2, in the exemplary embodiment shown, the fluids flow through the flow channels 3, 5 anti-parallel to one another, i.e. along the block transverse direction Y and opposite one another. This results in a counter-directional flow of the fluids in the flow channels 3, 5, which leads to increased efficiency of the heat exchanger.

Claims

Claims 1. Additively manufactured heat exchanger (1) for fluidically separated heat transfer between a first fluid and a second fluid, - with an additively manufactured heat exchanger block (2) which has a block longitudinal direction (X), a block transverse direction (Y) and a block height direction (Z) which run perpendicular to one another - wherein first flow channels (3) extending in the transverse direction (Y) of the heat transfer block (2) are formed in the heat transfer block (2), which first flow channels (3) penetrate the heat transfer block (2) and through which a first flow path (4) of a first fluid leads, - wherein second flow channels (5) extending in the transverse direction (Y) of the heat transfer block (2) are formed in the heat transfer block (2), which second flow channels (5) penetrate the heat transfer block (2) and through which a second flow path (6) of a second fluid, fluidically separated from the first flow path (4), leads, - with two first fluid chambers (7) which are formed at transverse ends (9) of the first flow channels (3) facing away from each other in the block transverse direction (Y), and which are fluidically connected to the first flow channels (3), so that the first flow path (4) leads through the first fluid chambers (7), - with two secondary fluid chambers (8) which are arranged in the block transverse direction (Y) on the side of the primary fluid chambers (7) facing away from the first flow channels (3), - wherein the second fluid chambers (8) are fluidically connected to the second flow channels (5), so that the second flow path (6) leads through the second fluid chambers (7), - wherein at least one of the second flow channels (5) leads through at least one of the first fluid chambers (7) to the second fluid chambers (8) adjacent to the first fluid chambers (7) in the block transverse direction (Y).

2. Heat exchanger according to claim 1, characterized in that at least one of the second fluid chambers (8) is located in the block transverse direction (Y) on the adjacent first fluid chambers (7), in particular immediately following the first fluid chambers (7).

3. Heat exchanger according to claim 1 or 2, characterized in that at least one of the second flow channels (5) leads through both of the first fluid chambers (7) to the second fluid chambers (8) adjacent to the respective first fluid chambers (7) in the block transverse direction (Y).

4. Heat exchanger according to one of claims 1 to 3, characterized in that at least one of the second flow channels (5), preferably the respective second flow channel (5), opens into the respective second fluid chambers (8) and is connected to the respective second fluid chambers (8).

5. Heat exchanger according to one of claims 1 to 4, characterized in that first flow channels (3) and second flow channels (5) follow one another in the block longitudinal direction (X).

6. Heat exchanger according to one of claims 1 to 5, characterized in that first flow channels (3) and second flow channels (5) in Block height direction (Z) follow one another.

7. System (100) with a heat exchanger (1) according to one of the preceding claims, - with a supply device (101 ) through which a first fluid flows during operation, - with a circuit (102) through which a second fluid circulates during operation, - wherein a first flow path (4) of the first fluid leads through the first fluid chambers (7) and the first flow channels (3) and a second flow path (6) of the second fluid leads through the second fluid chambers (8) and the second flow channels (5), so that during operation the first fluid flows through the first fluid chambers (7) and the first flow channels (3) and the second fluid flows through the second fluid chambers (8) and the second flow channels (5).

8. System according to claim 7, characterized in that the system (101) is designed such that the first fluid flows through the first flow channels (3) at a higher pressure than the second fluid flows through the second flow channels (5).

9. System according to claim 7 or 8, characterized in that the heat exchanger (1) in the system is operated as an evaporator (10) of the second fluid, so that the second fluid cools the first fluid.

10. Tank system (200), with at least one refueling point (201) for refueling a consumer (300) with a fuel and with a system (100) according to one of claims 7 to 9, wherein the fuel is the first fluid.

11. Tank system according to claim 10, characterized in that the fuel and thus the first fluid is a gas, in particular hydrogen or a hydrogen-containing gas.

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