Heat exchange member

Abstract

To increase the heat propagation efficiency of a heat exchange member.SOLUTION: The heat exchange member has a substrate with an upper surface. A plurality of fins are extended outward from the upper surface. The plurality of fins extend from the base to the tip and the distance between the base and the tip defines the height of each fin. A plurality of dimples are 3D-printed bodies having curved surfaces and are disposed among the plurality of fins or on the plurality of fins.SELECTED DRAWING: Figure 1

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is based on and claims the benefit of provisional application No. 63 / 637,526, entitled "Complex Dimple Shape for Improved Plate-Fin Heat Exchanger HTC," filed April 23, 2024, and application No. 18 / 914749, filed in Japan on October 14, 2024, the contents of which are incorporated by reference in their entireties. [Technical Field]

[0002] FIELD OF THE DISCLOSURE The present disclosure relates to a heat exchanger for improving heat transfer. In embodiments, the disclosure relates to a heat exchange element with dimples. [Background technology]

[0003] The performance, lifespan, and safety of many electrical components depend on the temperature at which they operate, and heat buildup can adversely affect these factors. The temperature of an electrical component can be affected by heat generated by the electrical component or its surrounding environment. Heat dissipation components are used to dissipate heat from electrical components and other heat-generating devices and prevent the adverse effects of heat buildup. Some heat dissipation components utilize plate fins or pin fins that extend outward from a base that is thermally coupled to the electrical component. As a fluid (e.g., air, water) flows along the surface of the fins and along the heat sink, the fins transfer heat from the electrical component to the fluid, cooling the electrical component.

[0004] Increasing the surface area of ​​a heat dissipation element can sometimes improve heat transfer from the heat dissipation element to the fluid. Increasing the surface area of ​​a heat dissipation element typically improves heat transfer through the heat dissipation element and convective heat transfer. However, increasing the surface area of ​​a heat dissipation element can impede fluid flow, reducing convective heat transfer efficiency and increasing pressure drop. Summary of the Invention

[0005] This specification describes embodiments of a heat exchange element for improving heat transfer efficiency. The heat exchange element includes a substrate having an upper surface. A plurality of fins extend outward from the upper surface. The plurality of fins extend from a base to a tip, and a distance between the base and the tip defines a fin height. A plurality of dimples are 3D printed with curved surfaces. The plurality of dimples are disposed between the plurality of fins or on each of the plurality of fins.

[0006] Another embodiment of the heat exchange member includes a substrate having a first side and a second side opposite the first side. The fins extend along a longitudinal direction from adjacent the first side to adjacent the second side and further extend outward from the top surface. The dimples have sides that converge at an apex. The sides have an upwardly convex parabolic shape. The dimples are disposed on the top surface between the fins or on the surface of the fins. The dimples are 3D printed.

[0007] Another embodiment of the heat exchange member includes a substrate having a top surface, a first side surface, and a second side surface opposite the first side surface. A plurality of fins extend outward from the top surface along a longitudinal direction from adjacent the first side surface to adjacent the second side surface. The fins extend from a base to a tip, and the distance between the base and the tip defines a fin height. The substrate defines a first set of dimples located on the top surface between the fins. The first set is also referred to as a first group. The dimples in the first set have a dimple height less than 30% of the fin height. The fins define a second set of dimples on the surfaces of the fins that is less than 30% of the fin height or greater than 70% of the fin height. The second set is also referred to as a second group. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 1 is a perspective view of a conventional heat exchange element with plate fins according to the prior art. [Figure 2] FIG. 2 is a top view of a conventional heat exchange element with pin fins according to the prior art. [Figure 3] FIG. 3 is a cross-sectional side view of a heat exchange element with straight plate fins and spherical dimples according to one embodiment of the present disclosure. [Figure 4] FIG. 4 illustrates a top view of a heat exchange element with non-linear plate fins and spherical dimples arranged in various patterns according to one embodiment of the disclosure. [Figure 5] FIG. 5 is a top view of a heat exchange element with pin fins and spherical dimples according to one embodiment of the present disclosure. [Figure 6] FIG. 6 is a side perspective view of the heat exchange element shown in FIG. [Figure 7] FIG. 7 is a cross-sectional side view of the heat exchange element shown in FIG. 3 with parabolic dimples according to one embodiment of the disclosure. [Figure 8A] FIG. 8A is a top view of an airfoil dimple according to one embodiment of the disclosure. [Figure 8B] FIG. 8B is a top view of an airfoil dimple according to one embodiment of the disclosure. [Figure 8C] FIG. 8C is a top view of an airfoil dimple according to one embodiment of the disclosure. [Figure 8D] FIG. 8D is a top view of an airfoil dimple according to one embodiment of the disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0009] Embodiments of the present disclosure are described below. However, it should be understood that the disclosed embodiments are merely examples, and that other embodiments may take various alternative forms shown and suggested. The figures are not necessarily to scale, and some features may be exaggerated or reduced to show the details of a particular component or portion. Therefore, specific structural and functional details disclosed in this specification should not be interpreted as limiting, but merely as a representative basis for teaching those skilled in the art that the embodiments can be variously used. As those skilled in the art will understand, various features illustrated and described with reference to any of the figures can be combined with features shown in one or more other figures to produce embodiments not explicitly illustrated or described. The combinations of illustrated features provide representative embodiments for typical applications. However, various combinations and modifications of features consistent with the teachings of this disclosure may be desired for particular applications or implementations.

[0010] As used in this specification, singular and plural terms should be understood to refer to both the singular and the plural, unless the context clearly indicates otherwise. As used in this specification, terms that indicate a relationship to a preceding object, such as above or above, should be understood to refer to both the same object as the preceding object and a different object, unless the context clearly indicates otherwise. By way of example, a "processor" programmed to perform various functions may refer to one processor programmed to perform all of the functions or to multiple processors collectively programmed to perform each of the various functions.

[0011] As shown in FIGS. 1 and 2 , according to the prior art, a heat exchange member 10 for dissipating heat from a heat-generating component (e.g., an electrical component, a computer component, an inverter card, etc.) that can generate heat includes a substrate 12 having an upper surface 14. The heat exchange member 10 is also referred to as a heat dissipation member or a heat sink. In the description of this specification, the heat exchange member 10 may also be referred to as a heat sink. The heat exchange member 10 may be attached to the heat-generating component via an outer plate, a thermally conductive paste, a connecting component between the heat exchange member 10 and the heat-generating component, etc.

[0012] The heat exchange element 10 may be connected to a housing that surrounds the heat exchange element 10. For example, the housing may include an outer plate that surrounds the substrate 12. The substrate 12 and the housing may define a passage for a heat transfer medium with which the substrate 12 exchanges heat. The heat transfer medium may be a fluid, such as water, air, a refrigerant, oil, a dielectric fluid, or other non-conductive heat transfer fluid. Consequently, the housing provides a passageway for exposing the substrate 12 to the fluid. The substrate 12 is also a part of the passageway. The fluid flows along the heat exchange element 10, as indicated by fluid flow F. In the illustrated example, the fluid enters from a first side 16, flows from the first side 16 to a second side 18 opposite the first side 16, and exits from the second side 18. The fluid flow may be generated by forced convection, such as by a pump, or by natural convection due to heat.

[0013] The fins 20 start from the top surface 14 of the substrate 12 and extend outward in a vertical direction from a base 22 to a tip 24. The fins 20 extend laterally along the substrate 12 from a first side surface 16 to a second side surface 18. The vertical direction is the normal direction of the substrate 12. The horizontal direction is the planar direction parallel to the top surface of the substrate 12. The fins 20 have a shape that can be called a plate fin, a pin fin, or the like.

[0014] In some embodiments, the fins 20 are plate fins arranged in longitudinal columns 26, with fluid flowing between the fins 20. Fluid may flow between the fins 20 or, alternatively, may recirculate through the spaces between the fins 20.

[0015] In some embodiments, the plurality of fins 20 are pin fins arranged in irregular or non-uniform columns 26, staggered, etc. The columns 26 formed by the plurality of fins 20 define channels 27 (e.g., spaces for fluid flow between at least two columns 26 of the plurality of fins 20) for fluid to flow from the first side 16 to the second side 18. The channels 27 are also referred to as fluid flow paths. The plurality of pin fins can have shapes including elliptical, airfoil, teardrop, circular, conical, rectangular, parabolic, or other known shapes, or combinations or sub-combinations thereof.

[0016] 3, 4, 5, 6, and 7, the heat exchange member 10 of the embodiment has a plurality of dimples 28 protruding from the upper surface 14 of the substrate 12 (i.e., extending outward from the substrate 12). The heat exchange member 10 includes a plurality of dimples 28. The dimples 28 may also be referred to as curved portions formed on a portion of the surface of the substrate 12, including the upper surface 14 of the substrate 12 and the surfaces of the plurality of fins 20.

[0017] In some embodiments, the top surface 14 of the substrate 12 defines a plurality of dimples 28. The plurality of dimples 28 can have a variety of shapes or cross-sectional areas.

[0018] In some embodiments, substrate 12 defines a plurality of dimples 28 that have a convex shape relative to top surface 14. In other words, dimples 28 have a spherical or curved shape (e.g., hemispherical, partial spherical, etc.) relative to top surface 14. Dimples 28 are arranged between two fins 20, between three or more fins 20, and / or in columns 26.

[0019] In some embodiments, the dimples 28 are positioned adjacent to or spaced apart from the base 22 of the fin 20. For example, the dimples 28 may be positioned proximate the base 22 of the fin 20 or may be positioned centrally in the columns 26 between the fins 20.

[0020] The dimples 28 increase the surface area of ​​the heat exchange element 10 along the substrate 12, improving the overall heat transfer coefficient. Increasing the surface area of ​​the heat exchange element 10 reduces the thermal resistance to heat transfer. Because heat transfer through the heat exchange element 10 can be a bottleneck for improving thermal performance, reducing the thermal resistance to heat transfer reduces the overall thermal resistance of the heat exchange element 10. Furthermore, because the relative fluid flow velocity is lowest adjacent the substrate 12 and / or base 22 of the fins 20, increasing the surface area of ​​the heat exchange element 10 does not significantly increase the pressure drop across the heat exchange element 10. In other words, although the dimples 28 may disrupt the fluid flow velocity along the substrate 12, this disruption increases the convective heat transfer coefficient without significantly increasing the pressure drop. For example, the dimples 28 may not significantly increase flow separation and / or fluid flow velocity reversal.

[0021] 3 and 4, the heat exchange member 10 of this embodiment has a plurality of dimples 28 that are arranged uniformly, non-uniformly, or in a predetermined pattern along the substrate 12. The arrangement of the plurality of dimples 28 can be a staggered arrangement, an arrangement including at least one column 32 (row) and / or row 33, or an arrangement including a plurality of columns 32 or a plurality of rows 33. The arrangement of the plurality of dimples 28 is also referred to as a pattern.

[0022] At least one channel 27 of the fins 20 may include a first column 32a of dimples 28 and a second column 32b of dimples 28. For example, the dimples 28 may have a first pattern 30a in which the dimples 28 in the first column 32a are staggered from top to bottom or bottom to top, as shown in the left channel 27. In another example, the dimples 28 in the channels 27 of the centrally illustrated fins 20 may have a second pattern 30b including a single column 32 of dimples 28 centrally positioned within one channel 27 of the fins 20.

[0023] In yet another example, the dimples 28 may have a third pattern 30c in the channel 27 of the fins 20 shown on the right, in which the dimples 28 in a first column 32a and the dimples 28 in a second column 32b are aligned with one another from top to bottom or bottom to top, such that the first column 32a and the second column 32b form a defined row 33. The placement of the dimples 28 may be selected to satisfy requirements such as heat transfer, fluid dynamics, pressure drop, and manufacturability.

[0024] In some embodiments, the plurality of dimples 28 may include a first dimple group including the plurality of dimples 28 and a second dimple group including the plurality of dimples 28. The plurality of dimples 28 of the first dimple group may be arranged in a first pattern 30a within the first channel 27, and the plurality of dimples 28 of the second dimple group may be arranged in a second pattern 30b within the second channel 27, where the second pattern 30b is different from the first pattern 30a. The first pattern 30a and / or the second pattern 30b may be replaced with a third pattern 30c, another pattern, etc.

[0025] In one embodiment, the arrangement of the dimples 28 may be a continuous, uniform arrangement or a discontinuous arrangement between the columns 26 of the at least two fins 20 and / or within the at least one channel 27. In other words, at least one channel 27 may include multiple arrangements of the dimples 28 and / or a combination of the first pattern 30a, the second pattern 30b, and / or the third pattern 30c. For example, at least one channel 27 may include a first pattern 30a extending from a position adjacent the first side 16 to a point between the first side 16 and the second side 18, and a second pattern 30b extending from a point between the first side 16 and the second side 18 to a position adjacent the second side 18.

[0026] 5 and 6 , the dimples 28 of the heat exchange member 10 of this embodiment may extend partially or completely from the fin 20 adjacent the base 22 of the fin 20. In other words, the dimples 28 may extend from the fin 20 but not from the substrate 12, or may extend from both the fin 20 and the substrate 12 near the base 22 of the fin 20. The dimples 28 may extend from any point along the outer surface of the fins 20 and / or from the periphery defined by the base 22 of the fins 20. For example, if the fin 20 is an elliptical pin fin, the dimples 28 may extend from the fin 20 along the periphery of the fin 20 from one vertex to another vertex.

[0027] In some embodiments, the heat exchange member 10 includes a plurality of fins 20 that are elliptical pin fins. The plurality of fins 20 are arranged in alternating columns 26 along the substrate 12, where a first end 34 a, or apex, of a first fin 20 a is adjacent to a second end 34 b, or apex, of a second fin 20 b. At least one of the plurality of dimples 28 extends from a portion of the first fin 20 a adjacent to the first end 34 a.

[0028] In some embodiments, the heat exchange member 10 includes a plurality of dimples 28 extending from the outer surface of at least one of the fins 20 .

[0029] In one embodiment, the dimples 28 are located within gaps 36 defined between the fins 20 by the predetermined arrangement of the fins 20, and extend from the upper surface 14 of the substrate 12 at the gaps 36. The gaps 36 may be defined as regions through which fluid flows between two fins 20 and / or between more than two fins 20. For example, the fins 20 may be arranged in longitudinally offset columns 26 of elliptical pin fins. In this case, the gaps 36 may be between or adjacent to the ends of two adjacent fins 20 within a common column 26. The gaps 36 may also be between two adjacent columns 26 of the fins 20, etc. Furthermore, the gaps 36 may be any combination or subset of the above examples.

[0030] In some embodiments, the channel 27 and the gap 36 may refer to the same location on the top surface 14 of the substrate 12 .

[0031] 7 , the dimples 28 of the heat exchange element 10 of this embodiment may have a concave parabolic shape or a convex parabolic shape. For example, each of the multiple dimples 28 may be defined by a central axis extending upward from the top surface 14 to a vertex 37 and a side surface 39 connecting the vertex 37 to the edge of a circular area on the top surface 14 that defines a predetermined area around the vertex 37. The side surface 39 has a shape that can also be called cone-like. The side surface 39 has a parabolic shape, and the outer edge of the side surface 39 is the vertex of the parabolic shape and is in contact with the top surface 14. In other words, the side surfaces 39 of the multiple dimples 28 have a concave or convex parabolic shape that meet at the vertex 37. The parabolic shape is an effective shape for improving the heat transfer efficiency of the heat exchange element 10 because it increases the surface area with a relatively small cross-sectional profile, such as in the direction of fluid flow F, the direction of the columns 26 of the fins 20, or the direction from the first side 16 to the second side 18.

[0032] 8A, 8B, 8C, and 8D, the plurality of dimples 28 of the heat exchange member 10 of this embodiment have an airfoil shape. The airfoil shape may be symmetrical, asymmetrical, flat-bottomed, cambered, or the like, or a combination or portion of a combination thereof.

[0033] In some embodiments, the plurality of dimples 28 may have a shape or cross-sectional profile such as rectangular, prismatic, elliptical, teardrop, circular, conical, or other known shapes, or a combination or portion of a combination thereof.

[0034] In one embodiment, the heat exchange member 10 may include a combination of multiple types of dimples 28 having different shapes and / or different cross-sectional areas. In other words, the multiple dimples 28 may include multiple shapes, including at least two different shapes, such as a first shape and a second shape. For example, multiple dimples 28 having hemispherical, parabolic, and airfoil shapes may be disposed between at least two columns 26 of the fin 20, within at least one channel 27, and / or within at least one gap 36.

[0035] The shape of the plurality of dimples 28 between the at least two columns 26, within the channel 27, and / or within the at least one gap 36 may transition. For example, the plurality of dimples 28 between the at least two columns 26, within the channel 27, and / or within the at least one gap 36 may transition from a hemispherical shape adjacent the first side 16, to a parabolic shape at a point between the first side 16 and the second side 18, to an airfoil shape adjacent the second side 18.

[0036] The dimples 28 between the at least two columns 26, within the channel 27, and / or within the at least one gap 36 may be arranged to form a predetermined pattern from the first side 16 to the second side 18, or to a point between the first side 16 and the second side 18. For example, the dimples 28 may have a first arrangement 30a including columns 32a, 32b. In this case, the first column 32a may include a plurality of hemispherical dimples 28, and the second column 32b may include a plurality of parabolic dimples 28. In another example, both the first column 32a and the second column 32b may include a plurality of symmetrical airfoil-shaped and asymmetrical dimples 28 alternating within the first column 32a and the second column 32b. In this case, for example, the first column 32a may include a pattern in which a plurality of symmetrically shaped dimples 28 are alternately arranged with a plurality of asymmetrically shaped dimples 28.

[0037] In some embodiments, a plurality of dimples 28 between at least two columns 26, within channels 27, and / or within at least one gap 36 may be positioned to guide fluid flow F within at least one column 26. The plurality of dimples 28 between at least two columns 26, within channels 27, and / or within at least one gap 36 may include a combination of shapes to control fluid velocity, flow rate, flow type, or other fluid dynamic characteristics. For example, a combination of airfoil shapes may be used to increase convective heat transfer by directing fluid toward the fins 20, increasing fluid velocity or flow rate near the fins 20, preventing or reducing fluid velocity reversal and / or flow separation, or any combination or portion thereof. In other words, a plurality of dimples 28 having asymmetric, flat-bottom, or chamfered shapes may be positioned adjacent to or proximate to the fins 20 to control fluid dynamic characteristics.

[0038] For example, in FIG. 4, the combination of multiple dimples 28 can control the dynamic properties of the fluid adjacent to the concave and convex portions of the fin 20 and / or at locations away from the fin 20 (i.e., within the central region of the channel 27).

[0039] As yet another example, in Figures 2, 5, and 6, the combination of multiple dimples 28 can prevent or reduce fluid velocity reversals and / or flow separation between the ends 34 of the fins 20.

[0040] 7 and 8A, the plurality of dimples 28 of the heat exchange member 10 of this embodiment are characterized by a dimple height 38 and a dimple length 40. The dimple height 38 of the plurality of dimples 28 may be expressed as a percentage (%) of the fin height 42. The fin height 42 is the distance between the base 22 of the fin 20 and the tip 24 of the fin 20.

[0041] In some embodiments, the dimple height 38 is less than the fin height 42. In some embodiments, the dimple height 38 is a value within a range between a lower limit percentage and an upper limit percentage of the fin height 42. The lower limit percentage may be 0%. The lower limit percentage may be greater than 0%. The lower limit percentage and / or the upper limit percentage may be 5.0%. For example, the dimple height 38 may be a value greater than 0% and less than 5.0% of the fin height 42. The dimple height 38 may be a value within a range of 5-10%, 10-25%, 25-50%, or 50-75% of the fin height 42. The lower limit percentage may be a value within any of the example ranges. The upper limit percentage may be a value within any of the example ranges. Ranges may be expressed in various formats, such as greater than or equal to, less than or equal to, greater than, less than, or the like. Furthermore, ranges may be combinations or subcombinations of the example ranges.

[0042] In some embodiments, the dimple height 38 may be expressed as a percentage (%) of the fin width 44. For example, the dimple height 38 may be greater than 0% and less than 5.0% of the fin width 44. Similarly, the dimple height 38 may be 5-10%, 10-25%, 25-50%, or 50-75%, etc., of the fin width 44. Furthermore, the dimple height 38 may be any combination or subset of the above exemplary combinations of the fin width 44.

[0043] 5, 6, and 7, in one embodiment, the dimples 28 may extend from the fin 20 away from the base 22. In other words, the dimples 28 may extend from the fin 20 at any point between the base 22 and the tip 24. The point between the base 22 and the tip 24 may be defined by a percentage (%) of the fin height 42. For example, the dimples 28 may extend from the fin 20. The dimples 28 may extend from a position or ranges between 0-10, 10-20, 20-30, 30-50, 50-75, or 75-100% of the fin height 42. For example, the dimples 28 may extend from the fin 20 at a position less than 30% of the fin height 42 (i.e., adjacent the base 22) or at a position greater than 70% of the fin height 42 (i.e., adjacent the tip 24). Generally, fluid flow velocities are lower in regions near the base 22 or tip 24 of the fins 20. The inclusion of dimples 28 in these low flow velocity regions increases the surface area of ​​the heat exchange element 10 without significantly increasing the pressure drop across the heat exchange element 10. Thus, the dimples 28 improve the overall heat transfer coefficient of the heat exchange element 10.

[0044] In some embodiments, the plurality of dimples 28 extend from the side surface 46 of the fin 20. In other words, the plurality of dimples 28 extend outward from the side surface 46 of the fin 20 toward the center of each channel 27.

[0045] In one embodiment, the plurality of dimples 28 may include a common or identical shape with various dimensions, such as a dimple height 38, a dimple length 40, or other dimensions (e.g., diameter, radius, chord, upper surface camber line, lower surface camber line). For example, the plurality of dimples 28 may have a hemispherical shape. Some of the plurality of dimples 28 have a first dimple height 38 and / or dimple length 40 that is greater than the second dimple heights 38 and / or dimple lengths 40 of the other dimples 28.

[0046] In some embodiments, the plurality of dimples 28 may have a variety of different shapes. The different shapes may be provided by different cross-sectional areas, different dimple heights 38, different dimple lengths 40, or other dimensions. For example, the heat exchange element 10 may include a plurality of first dimples 28 and a plurality of second dimples 28. In this case, the plurality of first dimples 28 may have a symmetric airfoil shape, and the plurality of second dimples 28 may have a cambered airfoil shape.

[0047] 8A , the plurality of dimples 28 of one embodiment has a leading edge 48 and a trailing edge 50, with the dimple length 40 defined by the distance between the leading edge 48 and the trailing edge 50. The leading edge 48 or the trailing edge 50 may be oriented to affect fluid flow across the substrate 12. As discussed above, the plurality of dimples 28 may have different shapes and / or cross-sectional areas. The cross-sectional area of ​​the plurality of dimples 28 along the dimple length 40 affects fluid flow across or around the plurality of dimples 28.

[0048] In some embodiments, the cross-sectional area of ​​the plurality of dimples 28 may vary (i.e., increase or decrease) from the leading tip 48 to the trailing tip 50. In some embodiments, the leading tip 48 generally faces the first side 16, and the trailing tip 50 generally faces the second side 18. In other words, the leading tip 48 is oriented or oriented toward the upstream side of the fluid flow F, i.e., facing away from the fluid flow F. The trailing tip 50 is oriented or oriented toward the downstream side of the fluid flow F, i.e., relatively in line with the fluid flow F.

[0049] 5, 6, and also 8A, in some embodiments, the leading edge 48 and / or trailing edge 50 of at least one of the plurality of dimples 28 is oriented or aligned with at least one gap 36, such that the shape and / or orientation of at least one of the plurality of dimples 28 prevents or reduces flow separation or fluid velocity reversals.

[0050] 4, the heat exchange element 10 of the embodiment includes a plurality of fins 20, which are plate fins having a nonlinear shape (i.e., wavy, curved, sinusoidal, convex, concave, curvilinear, etc., or a shape that defines peaks and / or valleys). The nonlinear shape of the plurality of fins 20 increases the surface area of ​​the fins 20 and acts as a reinforcing member for the structure of the fins 20. As previously mentioned, increasing the surface area of ​​the heat exchange element 10 reduces the thermal resistance to heat transfer, improving the heat transfer of the heat exchange element 10. Convective heat transfer is also increased without significantly increasing the pressure drop.

[0051] In some embodiments, the leading edge 48 of at least one of the plurality of dimples 28 may be oriented relative to at least one of the plurality of fins 20, with the trailing edge 50 facing the side surface 46 of at least one of the plurality of fins 20. In other words, the leading edge 48 of at least one of the plurality of dimples 28 may be oriented tangentially with respect to the curvature of at least one of the plurality of fins 20. For example, at least one of the plurality of dimples 28 may be disposed between a peak and a valley (defined by a wavy shape) of at least one of the nonlinearly shaped plurality of fins 20, and the leading edge 48 of at least one of the plurality of dimples 28 may be oriented tangentially with respect to the side surface 46 to control fluid inflow into, outflow from, or flow out of the valley.

[0052] The plurality of dimples 28 may be constructed of any material capable of transferring heat from a heat-generating component to a fluid (e.g., copper, aluminum, steel, a metal alloy, etc.) The plurality of dimples 28 may be formed by precision forging, additive manufacturing, die casting, CNC manufacturing, extrusion, etc.

[0053] In some embodiments, the dimples 28 are 3D printed and formed using additive manufacturing techniques, such as with metal powders. In particular, the use of additive manufacturing techniques allows for a precise, controlled, and repeatable method for manufacturing the dimples 28 such that the shape, size, and placement of the dimples 28 and / or columns 32 of the dimples 28 are consistent with desired heat transfer, fluid flow characteristics, pressure drop, and the like.

[0054] The dimples 28 are also referred to as 3D printed bodies or components with a curved surface formed by layering. The dimples 28 are formed using a 3D printer. A method for manufacturing the dimples 28 includes a layering step in which a layerable material, such as a paste containing a metal powder, is layered into a layered body having a predetermined three-dimensional shape using a 3D printer. The method for manufacturing the dimples 28 may also include a step of solidifying the layered body to form a 3D printed body, such as by sintering the metal powder or curing an adhesive contained in the paste.

[0055] While exemplary embodiments have been described above, these embodiments are not intended to describe all possible forms encompassed by the scope of the claims. The terms used in this specification are terms of description rather than limitation, and it should be understood that various changes can be made without departing from the spirit and scope of this disclosure. As noted above, features of various embodiments can be combined to form additional embodiments of the invention that may not be explicitly described or illustrated.

[0056] Although various embodiments have been described as offering advantages or being preferable over other embodiments or prior art implementations with respect to one or more desired characteristics, depending on the particular application and implementation, those skilled in the art should recognize that one or more features or characteristics may be traded off to achieve desired overall system attributes. These attributes include, but are not limited to, numerous factors, including, for example, cost, strength, durability, life cycle cost, marketability, appearance, packaging aspects, size, maintainability, weight, manufacturability, ease of assembly, etc. Thus, even if any embodiment is described as less desirable than other embodiments or prior art implementations with respect to one or more characteristics, these embodiments are not outside the scope of this disclosure and may be desirable for particular applications.

[0057] (Disclosure of technical ideas) This specification discloses multiple technical ideas described in the following multiple clauses. Some clauses may be written in a multiple dependent form, with the subsequent clause referring to the preceding clause as an alternative. Furthermore, some clauses may be written in a multiple dependent form, referring to another multiple dependent clause. These multiple dependent clauses define multiple technical ideas.

[0058] (Technical thought 1) a substrate having a top surface; a plurality of fins extending outwardly from the upper surface, the fins extending from a base to a tip, the fins having a fin height defined by the distance between the base and the tip; A plurality of dimples that are 3D printed bodies with curved surfaces, A heat exchange element, wherein the plurality of dimples are disposed between the plurality of fins or on each of the plurality of fins.

[0059] (Technical thought 2) In the heat exchange element according to Technical Idea 1, The fins define a plurality of channels along a longitudinal direction across the upper surface, A plurality of the dimples are disposed between at least one of the channels.

[0060] (Technical Thought 3) In the heat exchange element according to Technical Concept 2, the plurality of fins partition a first channel and a second channel; The plurality of dimples includes a first dimple group and a second dimple group, the first dimple group being arranged in a first pattern within the first channel, and the second dimple group being arranged in a second pattern within the second channel, the second pattern being different from the first pattern.

[0061] (Technical Thought 4) In the heat exchange element according to any one of Technical Ideas 1 to 3, The dimples are arranged on the fins in an area that is less than 30% of the fin height or more than 70% of the fin height.

[0062] (Technical Thought 5) In the heat exchange element according to any one of Technical Ideas 1 to 4, At least one of the plurality of dimples extends outwardly from at least one of the plurality of fins adjacent a base of at least one of the plurality of fins.

[0063] (Technical Thought 6) In the heat exchange element according to any one of Technical Ideas 1 to 5, At least one of the plurality of dimples is disposed adjacent to a first end of the first fin and a second end of the second fin; The first fins and the second fins are arranged in a common row.

[0064] (Technical Thought 7) a substrate having a top surface, a first side, and a second side opposite the first side; a plurality of fins extending outwardly from the top surface along a longitudinal direction from a position adjacent the first side to a position adjacent the second side; a plurality of dimples having sides with a parabolic shape converging at an apex; the dimples are arranged on the upper surface between the fins or on the surface of the fins; A heat exchange member, wherein the plurality of dimples are 3D printed dimples.

[0065] (Technical Thought 8) In the heat exchange element according to Technical Concept 7, a plurality of said fins defining at least one channel; the plurality of dimples include a first dimple group and a second dimple group, The dimples of the first dimple group are arranged in a first pattern within at least one of the channels, and the dimples of the second dimple group are arranged in a second pattern within at least one of the channels, the second pattern being different from the first pattern.

[0066] (Technical Thought 9) In the heat exchange element according to Technical Concept 8, At least one of the channels includes a plurality of the dimples in the first pattern adjacent to the first side and a plurality of the dimples in the second pattern adjacent to the second side.

[0067] (Technical Thought 10) In the heat exchange element according to any one of Technical Ideas 7 to 9, the plurality of dimples include a first shape and a second shape; a plurality of said fins defining at least one channel; At least one of the channels includes a plurality of the dimples having the first shape and a plurality of the dimples having the second shape.

[0068] (Technical Thought 11) In the heat exchange element according to any one of Technical Ideas 8 to 10, At least one of the channels includes a plurality of the dimples of the first shape adjacent to the first side surface and a plurality of the dimples of the second shape adjacent to the second side surface.

[0069] (Technical Thought 12) In the heat exchange element according to any one of Technical Ideas 7 to 11, the plurality of dimples include a first group of dimples arranged in a first pattern and a second group of dimples arranged in a second pattern; the plurality of dimples include a first shape and a second shape; a plurality of said fins defining at least one channel; The plurality of dimples arranged in at least one of the channels includes a plurality of dimples arranged in the first pattern and a plurality of dimples arranged in the second pattern, and includes dimples of the first shape and dimples of the second shape.

[0070] (Technical Thought 13) In the heat exchange element according to any one of Technical Ideas 7 to 12, The parabolic shape may be concave or convex.

[0071] (Technical Thought 14) a substrate having a top surface, a first side, and a second side opposite the first side; a plurality of fins extending outward from the top surface along a longitudinal direction from a position adjacent to the first side surface to a position adjacent to the second side surface; The fins extend from a base to a tip, a fin height of the fin defined by the distance between the base and the tip; the substrate defines a first set of dimples located on the top surface between the fins; a dimple height of the first set of dimples is less than 30% of the fin height; A heat exchange element wherein the fins define a second set of the dimples located on a surface of the fins that is less than 30% of the fin height or more than 70% of the fin height.

[0072] (Technical Thought 15) In the heat exchange element according to Technical Idea 14, the first set of dimples has a leading edge and a trailing edge opposite the leading edge; The leading or trailing edge is oriented relative to at least one gap between at least two adjacent ends of the fins in a common row.

[0073] (Technical Thought 16) In the heat exchange element according to Technical Idea 14, the first set of dimples has a leading edge and a trailing edge opposite the leading edge; the plurality of fins are nonlinear plate fins; The leading edge of at least one of the first set of dimples is oriented tangentially to the curvature surface of at least one of the fins to control fluid flow along the substrate.

[0074] (Technical Thought 17) In the heat exchange element according to any one of Technical Ideas 14 to 16, a plurality of said fins defining at least one channel; At least one of the channels includes at least two of the first set of the plurality of dimples having a common shape and different dimensions.

[0075] (Technical Thought 18) In the heat exchange element according to any one of Technical Ideas 14 to 17, The first set of the plurality of dimples includes a symmetric airfoil shape and a cambered airfoil shape.

[0076] (Technical Thought 19) In the heat exchange element according to Technical Idea 18, a plurality of said fins defining at least one channel; The first set of dimples having the symmetric airfoil shape are centrally located within at least one of the channels, and the first set of dimples having the cambered airfoil shape are located adjacent to a plurality of fins that define at least one of the channels.

[0077] (Technical Thought 20) In the heat exchange element according to any one of Technical Ideas 14 to 19, the first set of dimples includes a first airfoil shape and a second airfoil shape; the first set of dimples having the first airfoil shape are disposed adjacent to the first side; The first set of dimples having the second airfoil shape are spaced apart from the first side surface.

Claims

1. a substrate having a top surface; a plurality of fins extending outwardly from the upper surface, the fins extending from a base to a tip, the fins having a fin height defined by the distance between the base and the tip; a plurality of dimples that are 3D printed bodies having curved surfaces; A heat exchange element, wherein the plurality of dimples are disposed between the plurality of fins or on each of the plurality of fins.

2. The heat exchange element according to claim 1, The fins define a plurality of channels along a longitudinal direction across the upper surface, A plurality of the dimples are disposed between at least one of the channels.

3. The heat exchange element according to claim 2, the plurality of fins partition a first channel and a second channel; The plurality of dimples includes a first dimple group and a second dimple group, the first dimple group being arranged in a first pattern within the first channel, and the second dimple group being arranged in a second pattern within the second channel, the second pattern being different from the first pattern.

4. The heat exchange element according to claim 1, The dimples are arranged on the fins in an area that is less than 30% of the fin height or more than 70% of the fin height.

5. The heat exchange element according to claim 2, At least one of the plurality of dimples extends outwardly from at least one of the plurality of fins adjacent a base of at least one of the plurality of fins.

6. The heat exchange element according to claim 1, At least one of the plurality of dimples is disposed adjacent to a first end of the first fin and a second end of the second fin; The first fins and the second fins are arranged in a common row.

7. a substrate having a top surface, a first side, and a second side opposite the first side; a plurality of fins extending outwardly from the top surface along a longitudinal direction from a position adjacent the first side to a position adjacent the second side; a plurality of dimples having sides with a parabolic shape converging at an apex; the dimples are arranged on the upper surface between the fins or on the surface of the fins; A heat exchange element, wherein the plurality of dimples are 3D printed dimples.

8. The heat exchange element according to claim 7, a plurality of said fins defining at least one channel; the plurality of dimples include a first dimple group and a second dimple group, The dimples of the first dimple group are arranged in a first pattern within at least one of the channels, and the dimples of the second dimple group are arranged in a second pattern within at least one of the channels, the second pattern being different from the first pattern.

9. The heat exchange element according to claim 8, At least one of the channels includes a plurality of the dimples in the first pattern adjacent to the first side and a plurality of the dimples in the second pattern adjacent to the second side.

10. The heat exchange element according to claim 7, the plurality of dimples include a first shape and a second shape; a plurality of said fins defining at least one channel; At least one of the channels includes a plurality of the dimples having the first shape and a plurality of the dimples having the second shape.

11. The heat exchange element according to claim 10, At least one of the channels includes a plurality of the dimples of the first shape adjacent to the first side and a plurality of the dimples of the second shape adjacent to the second side.

12. The heat exchange element according to claim 7, the plurality of dimples include a first group of dimples arranged in a first pattern and a second group of dimples arranged in a second pattern; the plurality of dimples include a first shape and a second shape; a plurality of said fins defining at least one channel; The plurality of dimples arranged in at least one of the channels includes a plurality of dimples arranged in the first pattern and a plurality of dimples arranged in the second pattern, and includes dimples of the first shape and dimples of the second shape.

13. The heat exchange element according to claim 7, The parabolic shape may be concave or convex.

14. a substrate having a top surface, a first side, and a second side opposite the first side; a plurality of fins extending outward from the top surface along a longitudinal direction from a position adjacent to the first side surface to a position adjacent to the second side surface; The fins extend from a base to a tip, a fin height of the fin defined by the distance between the base and the tip; the substrate defines a first set of dimples located on the upper surface between the fins; a dimple height of the first set of dimples is less than 30% of the fin height; A heat exchange element wherein the fins define a second set of the dimples located on a surface of the fins that is less than 30% of the fin height or more than 70% of the fin height.

15. The heat exchange element according to claim 14, the first set of dimples has a leading edge and a trailing edge opposite the leading edge; The leading or trailing edge is oriented relative to at least one gap between at least two adjacent ends of the fins in a common row.

16. The heat exchange element according to claim 14, the first set of dimples has a leading edge and a trailing edge opposite the leading edge; the plurality of fins are nonlinear plate fins; The leading edge of at least one of the first set of dimples is oriented tangentially to the curvature surface of at least one of the fins to control fluid flow along the substrate.

17. The heat exchange element according to claim 14, a plurality of said fins defining at least one channel; At least one of the channels includes at least two of the first set of the plurality of dimples having a common shape and different dimensions.

18. The heat exchange element according to claim 14, The first set of the plurality of dimples includes a symmetric airfoil shape and a cambered airfoil shape.

19. The heat exchange element according to claim 18, a plurality of said fins defining at least one channel; The first set of dimples having the symmetric airfoil shape are centrally located within at least one of the channels, and the first set of dimples having the cambered airfoil shape are located adjacent to a plurality of fins that define at least one of the channels.

20. The heat exchange element according to claim 14, the first set of dimples includes a first airfoil shape and a second airfoil shape; the first set of dimples having the first airfoil shape are disposed adjacent to the first side; The first set of dimples having the second airfoil shape are spaced apart from the first side.

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