Metal heat exchanger assembly via laminated object manufacturing

Abstract

Methods and systems for the laminated object manufacturing of heat exchangers. Some embodiments include a method that includes patterning a plurality of metal sheets so that the metal sheets include a plurality of base regions and a plurality of fin regions, wherein at least one of the fin regions is separated from an adjacent fin region by a gap; and applying at least one of pressure or heat to bond the base regions into at least one solid structure and bond the fin regions into a plurality of fins while preserving the gaps between bonded fin regions, wherein each bonded fin region is attached to at least one bonded base region.

Description

METAL HEAT EXCHANGER ASSEMBLY VIA LAMINATED OBJECT MANUFACTURINGCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims the benefit of and priority to United States Provisional Application No. 63 / 647,561, filed on May 14, 2024, the entire disclosure of which is hereby incorporated by reference as if set forth in its entirety herein.TECHNICAL FIELD

[0002] Embodiments described herein generally relate to methods and apparatus for fabricating metal laminated object parts, and more specifically to the manufacture of metal heat exchangers via laminated object manufacturing.BACKGROUND

[0003] Metal heat exchangers, such as heat sinks, may be manufactured using a variety of manufacturing processes including forging, machining, and additive processes. For example, heat sinks may be assembled via laminated object manufacturing (LOM), which involves assembling complex 3D structures by sequentially depositing layers of material. Each successive layer may be bonded to and / or deposited on the previous layer to gradually assemble the 3D structure.

[0004] Heat exchangers that include fin structures, however, present manufacturing challenges when fabricated using additive manufacturing processes. In additive manufacturing processes, delicate features such as fins often require dedicated support structures during bonding or deposition. The minimum spacing between adjacent features must accommodate support placement and removal, which can constrain the geometry, density, and orientation of fins during the manufacturing process. Other approaches such as machining or forging similarly face limitations in manufacturing complex fin arrays, often requiring extensive time, labor, and cost.

[0005] Accordingly, a need exists for improved methods of manufacturing metal heat exchangers.SUMMARY

[0006] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description section. This summary is not intended to identify or exclude key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

[0007] In one aspect, embodiments relate to a method to produce a heat exchanger via laminated object manufacturing, the method including patterning a plurality of metal sheets so that the metal sheets include a plurality of base regions and a plurality of fin regions, wherein at least one of the fin regions is separated from an adjacent fin region by a gap; and applying at least one of pressure or heat to bond the base regions into at least one solid structure and bond the fin regions into a plurality of fins while preserving the gaps between bonded fin regions, wherein each bonded fin region is attached to at least one bonded base region.

[0008] In some embodiments, each metal sheet comprises at least a portion of a base region.

[0009] In some embodiments, at least one fin has a thickness of a single metal sheet or less.

[0010] In some embodiments, each bonded fin region is attached at an angle offset to at least one bonded base region.

[0011] In some embodiments, the base regions comprise a channel to facilitate the flow of a coolant.

[0012] In some embodiments, the channel may function as a thermosiphon.

[0013] In some embodiments, each base region is adjacent to another base region to facilitate bonding.

[0014] In some embodiments, the method further includes depositing inhibitory material on at least one surface between a fin region and an adjacent fin region.

[0015] In some embodiments, at least one metal sheet includes an alignment feature for allowing the heat exchanger to interface with an external part.

[0016] In some embodiments, at least one fin is connected to an adjacent fin by a bridging section.

[0017] In some embodiments, at least one fin includes a uniform cross section.

[0018] In some embodiments, at least one fin includes at least one of a wavy geometry or a notched geometry.

[0019] In some embodiments, at least one fin includes a pattern of at least one hole or gap.

[0020] In another aspect, embodiments relate to a system for manufacturing a laminated object heat exchanger, the system including a laminated object manufacturing device configured to pattern a plurality of metal sheets so that the metal sheets include a plurality of base regions and a plurality of fin regions, wherein at least one of the fin regions is separated from an adjacent finregion by a gap; and a pressor configured to apply at least one of pressure or heat to bond the base regions into at least one solid structure and bond the fin regions into a plurality of fins while preserving the gaps between bonded fin regions, wherein each bonded fin region is attached to at least one bonded base region.

[0021] In some embodiments, each metal sheet includes at least a portion of a base region.

[0022] In some embodiments, at least one fin has a thickness of a single metal sheet or less.

[0023] In some embodiments, the base regions comprise a channel to facilitate the flow of a coolant.

[0024] In some embodiments, each base region is adjacent to another base region to facilitate bonding.

[0025] In some embodiments, at least one fin is connected to an adjacent fin by a bridging section.

[0026] In some embodiments, at least one fin includes at least one of a wavy geometry or a notched geometry.

[0027] In some aspects, embodiments relate to a heat exchanger formed via a laminated object manufacturing process, the process including patterning a plurality of metal sheets so that the metal sheets include a plurality of base regions and a plurality of fin regions, wherein at least one of the fin regions is separated from an adjacent fin region by a gap; and applying at least one of pressure or heat to bond the base regions into at least one solid structure and bond the fin regions into a plurality of fins while preserving the gaps between bonded fin regions, wherein each bonded fin region is attached to at least one bonded base region.BRIEF DESCRIPTION OF DRAWINGS

[0028] Non-limiting and non-exhaustive embodiments of this disclosure are described with reference to the following figures, wherein like reference numerals refer to like parts throughout the various views unless otherwise specified:

[0029] Figure 1 illustrates a side view of a metal part;

[0030] Figure 2 illustrates an isometric view of the metal part of Figure 1;

[0031] Figure 3 illustrates a side view of a metal part;

[0032] Figure 4 illustrates an isometric view of the metal part of Figure 3;

[0033] Figure 5 illustrates an isometric view of a metal part; and

[0034] Figure 6 illustrates a cutaway of the isometric view of Figure 5.DETAILED DESCRIPTION

[0035] Various embodiments are described more fully below with reference to the accompanying drawings, which form a part hereof, and which show specific exemplary embodiments. However, the concepts of the present disclosure may be implemented in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided as part of a thorough and complete disclosure, to fully convey the scope of the concepts, techniques and implementations of the present disclosure to those skilled in the art. Embodiments may be practiced as methods, systems or devices. The following detailed description is, therefore, not to be taken in a limiting sense.

[0036] Reference in the specification to “one embodiment” or to “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiments is included in at least one example implementation or technique in accordance with the present disclosure. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment.

[0037] In addition, the language used in the specification has been principally selected for readability and instructional purposes and may not have been selected to delineate or circumscribe the disclosed subject matter. Accordingly, the present disclosure is intended to be illustrative, and not limiting, of the scope of the concepts discussed herein.Definitions

[0038] Unless otherwise specified, the following terms as used herein shall have the meanings as provided below:

[0039] The term “laminated object manufacturing” (LOM) refers to a method of manufacturing a part, containing additive and subtractive steps, beginning with contiguous sheets of material and processing sheets sequentially to form a part.

[0040] The term “bonding” refers to the process through which the contiguous sheets of material are formed into a part. The workpiece is subjected to heat and / or applied force which form covalent and / or metallic bonds between the sheets of material, forming an object.

[0041] The term “part” refers to a heat exchanger or other object manufactured through LOM.

[0042] The term “base” refers to a portion of a part which has at least one fin attached.

[0043] The term “fin” refers to a thin, high aspect ratio portion of a part which is attached to a base.

[0044] The term “face” refers to a surface on a fin which has a high surface area.

[0045] The term “edge” refers to a surface on a fin which has a small surface area.

[0046] The term “workpiece” refers to a stack of metal sheets to be bonded into at least one part.

[0047] The term “metal sheet” refers to a metal sheet or foil that is stacked in the workpiece. Each metal sheet may be patterned to contain part regions and support structure regions. In some embodiments, the metal sheet may comprise at least one of aluminum, copper, magnesium, titanium, aluminum alloy, magnesium alloy, and / or titanium alloy.

[0048] The term “sheet” refers generally to a metallic layer between 25 pm to 10 cm in thickness.

[0049] The term “void” refers to a volume cut out of a metal sheet in the support or part region which is fully enclosed and not fluidically connected to any other internal channel or port within the workpiece.

[0050] The term “flow path” refers to a traceable path of void space through internal channels in the part from at least one external port to at least a second external port.

[0051] The term “channel” refers to at least a portion of the void space in the flow path.Embodiments

[0052] Embodiments of this invention include configurations of heat exchangers formed using laminated object manufacturing (LOM). The configurations may include heat sinks formed from a plurality of patterned metal sheets. The metal sheets may be patterned to include base regions and fin regions. The metal sheets may be assembled and bonded to form a heat exchanger with a base and a plurality of fins.

[0053] Such configurations may have various benefits over traditional techniques for forming heat exchangers. For example, the fins of the heat exchangers can be made thinner and placed closer together than in traditional techniques, at least because complex support materials do not need to be inserted between the fins. Avoiding the need for complex support structures can also improve manufacturing efficiency. The configurations also allow for complex, tailored geometries (e.g., wavy edges) and features (e.g., alignment features, holes, etc.) without relying on complicated manufacturing processes or post-processing.

[0054] Non-limiting examples of these configurations are further discussed below.Workpiece

[0055] In laminated object manufacturing, a workpiece consisting of a plurality of metal sheets may be assembled and bonded. The workpiece may be assembled in a laminated fashion from the metal sheets. In this manner, the workpiece may be a layered workpiece assembled by depositing the metal sheets. The metal sheets may be patterned such that the pattern of the metal sheets partitions the workpiece into at least one support region and at least one part region. In some embodiments, each metal sheet may be at most 1 mm thick. The metal sheets may be bonded in a heated press, a more complicated bonding machine comprising a heated press and a vacuum chamber, and / or a bonding machine of any configuration appropriate for laminated object manufacturing of metal parts. The metal sheets may be bonded by applying a mechanical force along at least one axial direction of the metal sheets.

[0056] In some embodiments, the part regions may be assembled within a build volume of the workpiece. The build volume may be defined as the geometric volume enclosed by the external faces of the stack of patterned metal sheets.

[0057] In some embodiments, each part region may have a unique pattern which comprises a cross-sectional slice of the final part. For example, the part regions may correspond to a heat sink and / or other heat exchangers (collectively referred to as “parts”) configured to be formed within the build volume of the workpiece. The part may include fins that are formed from at least one fin region within the part regions. In some embodiments the fin regions may be oriented so that individual fins of the part are oriented parallel with at least one base region. In some embodiments, the part regions may be oriented so that individual fins are oriented perpendicular or at some offset angle to at least one base region. The orientation may be selected based on the desired mechanical properties, flow characteristics, and / or constraints of the LOM process.

[0058] In some embodiments, the part regions may be patterned to transmit compressive force through the part regions (e.g., axially) during the bonding process. This may ensure full bonding of the metal sheets across the part regions. In some embodiments, the force may be transmitted through a portion of the part regions. For example, the force may be transmitted through at least one base region of the part and not transmitted through at least one fin region (e.g., to reduce deformation and / or buckling). The base regions may have sufficient thickness and stiffness to maintain structural integrity under LOM pressure and / or temperature levels.

[0059] In other embodiments, at least one support region may be positioned between fins of the part. The support regions may be treated and / or coated with an inhibitory material (e.g., a polymeric release film, an oxide-forming compound, a metal oxide, carbon or another inert material, etc.) that prevents permanent bonding between adjacent regions (e.g., adjacent fins) while still allowing compressive force to be transmitted between adjacent regions. In some embodiments, these support regions may further include deformable features such as tabs, ridges, and / or patterned cutouts designed to control local bonding pressures and / or fracturing between regions.

[0060] In some embodiments, after bonding, the workpiece may be subjected to a mechanical forming process to form a part from the workpiece. The part regions may be separated from at least a portion of the support regions. The part regions may be fully extracted from the support regions prior to being formed into the part. The forming process may consist of mechanical translations such as pressing, stamping, bending, hydroforming, and / or other processes that alter the geometry of the part regions. The part regions may then be finished with various post-forming processes.Base Configurations

[0061] In some embodiments, the workpiece may include at least one base region. The base region may be patterned to serve as a structural foundation for the fins of the part by forming at least a portion of a base for the part. Each metal sheet may include at least a portion of the base region. During the forming process, multiple base regions may be bonded together to form the base. Each base region may be adjacent to another base region for bonding. The base region may provide mechanical support, thermal conduction, and / or fluid routing functions within the part. In some embodiments, the base may connect to fins on a single surface. Alternatively and / or additionally, the base may connect to fins on multiple surfaces or edges.

[0062] In some embodiments, the base may include alignment and / or registration features to facilitate integration of the part regions with other components. Such features may include through-holes, slots, detents, keyed recesses, raised bosses, and / or interlocking edge geometries. The features may be used for locating the part regions within a larger assembly, enabling rotational or translational alignment, and / or for securing the part using mechanical fasteners, adhesives, and / or weldments. The features may be incorporated within the patterns of the metal sheets during the LOM process. The features may be filled or coated with adhesives, gaskets, and / or thermal interface materials.

[0063] In some embodiments, at least one surface of the base may be non-planar or contoured to follow a predefined curvature. For example, the base may include a cylindrical, spherical, and / or freeform geometry. This may enable improved thermal contact with curved heat sources and / or integration into systems with complex spatial constraints. The perimeter of the base may include any suitable geometry, such as non-rectilinear geometries including elliptical, polygonal, notched, and / or arcuate geometries.

[0064] In some embodiments, the base may include at least one flow channel. The flow channel may form flow paths to allow the flow of liquid and / or gas through the base. The flow channel may be formed from void spaces within the part regions. The void spaces may be formed via any appropriate cutting technique, such as drag knife cutting, laser cutting, and / or etching. Each void space may define a portion of the internal flow path through the part.

[0065] In some embodiments, the channel may extend longitudinally, transversely, and / or in a serpentine or branching pattern through the base. The channel may be connected to at least one externally accessible port that enables the flow of gas and / or liquid into or out of the base. In some embodiments, multiple ports may be located on multiple external faces of the base to enable crossflow or counterflow arrangements.

[0066] In some embodiments, the ports may have similar and / or identical dimensions. In some embodiments, the ports may have a dimension of at least 500 pm. In some embodiments, the ports may have a dimension less than 5 cm.

[0067] In some embodiments, the flow channel may have a uniform thickness along a flow path through the base with respect to a plane of the part. In some embodiments, the thickness of the channels may be at least the thickness of a single metal sheet. In some embodiments, the thickness of the channels may be a multiple of the thickness of a single metal sheet.

[0068] In some embodiments, the channel may be enclosed with some quantity of fluid that vaporizes at a desired temperature, and subsequently sealed. This channel may function as a thermosiphon which passively increases heat transfer from the heat source to the base of the fins. In embodiments where fins are comprised of multiple layers, the thermosiphon may extend into at least part of the fin.

[0069] In some embodiments, the base may include reinforcement features such as ribs, gussets, and / or thickened regions to enhance load-bearing capacity or provide rigidity during bonding and / or post-processing. In some embodiments, the base region may include holes and / or gaps for weight reduction and / or integration with sensors, electronics, and / or other external partsor elements. For example, the base region may include isolation trenches, shielded chambers, and / or conformal slots to accommodate cables, signal routing, and / or electrical shielding elements.Fin Configurations

[0070] In some embodiments, the formed part may include at least one fin configured to extend from the base. The fin may be patterned such that the fin is open to convective or radiative heat transfer on at least two surfaces upon removal of the support regions. The fin may be vertically, horizontally, or obliquely oriented relative to the axis of force applied to the workpiece.

[0071] In some embodiments, the part may include multiple fins to form a fin array. The fin array may include rows or columns of fins, which may be aligned in parallel, staggered, and / or offset arrangements. Adjacent fins may be separated by air gaps. The air gaps may be present between fin regions of the workpiece and may be preserved during the forming process. The air gaps may be of any suitable thickness, such as the thickness of the fin and / or a single metal sheet (and / or a multiple thereof). In some embodiments, the air gaps may be uniform across the entire array. In some embodiments, the air gaps may vary across the fin array.

[0072] In some embodiments, the fin may be free-standing and connected to the base along a single edge, a portion of a single edge, and / or multiple edges. The edge of the fin may be traced along a cut boundary of a metal sheet. The faces of the fin may have a thickness of a single metal sheet or less. In some embodiments, the fin may be connected to two separate bases, with connections formed at least one edge. This may enhance mechanical stiffness and / or enable multidirectional heat transfer. In some embodiments, multiple fins may be arranged on multiple faces (e.g., opposing faces) of a base region.

[0073] In some embodiments, multiple fins may be connected via bridging sections. The bridging sections may align fins to maintain gaps between fins and the structural integrity of the fins. The bridging sections may transmit force through the workpiece during the bonding process without permitting adhesion between the fins. The bridging sections may be formed from part regions of the workpiece.

[0074] In some embodiments, the fin regions may include at least one channel. Flow paths within the fin may be formed from channels to introduce coolant, gas, and / or other fluids through the fin. The flow paths may improve internal convective heat transfer and / or enable secondary thermal regulation. In some embodiments, the flow channel may pass through the bridging section and / or the base of the part.

[0075] In some embodiments, the fin may be configured with a uniform cross-section. In some embodiments, the fins may have a rectangular cross-section. The thickness of the fin may be uniform, such as a multiple of the thickness of a metal sheet or a fraction of the thickness of a metal sheet. In some embodiments, the fin may be tapered, with the base formed from multiple metal sheets and then transitioning to a single-sheet thickness at the distal tip of the fin. In some embodiments, both uniform and tapered fins may be formed within the same part.

[0076] In some embodiments, the surfaces of the fin may be treated with an inhibitory material. The inhibitory material may be configured to selectively prevent bonding between selected regions. For example, the inhibitory material may prevent bonding between adjacent fin surfaces. The inhibitory material may be deposited on at least one surface prior to and / or during the bonding process. The inhibition material may include a release film, an oxide coating, a carbon-containing compound, and / or other non-bonding interface. In some embodiments, the fin surfaces may remain untreated, allowing for full bonding continuity across the laminated stack. In such embodiments, after bonding the fin may be selectively separated from adjacent regions using mechanical separation, thermal debonding, and / or chemical etching processes.

[0077] Figure 1 illustrates a side view of a metal part 100. The metal part 100 may be manufactured by assembling and bonding a plurality of metal sheets using LOM. The metal part 100 may include a plurality of fins 102 extending from a base 104. As shown, each fin 102 may have the thickness of a single metal sheet. The fins 102 may have a uniform and / or rectangular cross-section. Adjacent fins 102 may be separated by gaps 106. Each gap 106 may have the thickness of a single metal sheet and / or otherwise be uniform in thickness.

[0078] Figure 2 illustrates an isometric view of the metal part 100. As shown, the metal part 100 may include a support region 202. The support region 202 may support the manufacturing of the metal part 100. For example, as shown, the support region 202 extends from the base 104 further than the fins 102 to support and / or protect the fins 102 and / or other regions during manufacturing. The support region 202 may be removed to form the final part.Fin Patterning

[0079] In some embodiments, the fin may be configured with varying heights, widths, and / or sizes across the extent of the part. The height of individual fins may be determined during the LOM process by varying the number of metal sheets comprising each fin. In some embodiments, the distal tips and / or extreme edges of the fin may be arranged to follow a prescribed curvature or perimeter of another region and / or part, such as external heat sinks, cold plates, heat pipes,electronic modules, enclosure frames, and / or mounts. In some embodiments, at least one dimension of the fin (e.g., the height of the fin) may be at least 10 times greater than the thickness of the fin.

[0080] In some embodiments, at least one face or edge of the fin may include a non-uniform or complex geometry. The geometry may include wavy, sinusoidal, serrated, notched, and / or undulating edges. The geometry may enhance mixing of airflow, interrupt laminar boundary layers, and / or allow integration with other parts.

[0081] In some embodiments, the geometry of the fin may be patterned to promote, enhance, and / or direct airflow through and / or across the fin. For instance, multiple fins may be arranged in spatial patterns that generate converging or diverging flow channels and / or guide airflow in particular directions, such as a helical, oscillatory, or cross-flow direction. In some embodiments, the fin may be integrated with standing posts, pin arrays, and / or protruding ribs.

[0082] In some embodiments, the fin may include surface-level patterns that increase the effective surface area of the fin. For example, the fin may be patterned to include surface textures such as ridges, dimples, and / or micro-scale protrusions, which increase contact area with surrounding air or fluids. In some embodiments, the surface-level patterns may cover the entire surface of the fin. In some embodiments, the surface-level patterns may be located along selected regions of the fin, such as regions with high heat flux.

[0083] In some embodiments, the fin may include attachment features, such as tabs, slots, and / or raised surface features. The attachment features may allow mechanical fastening, thermal contact, and / or engagement with other parts. The attachment features may be concentrated near the edges.

[0084] Figure 3 illustrates a side view of a metal part 300. The metal part 300 may be manufactured by assembling and bonding a plurality of metal sheets using LOM. The metal part 300 may include a plurality of fins 302 extending from a base 304. As shown, the metal part 300 may include an alignment feature 306 that protrudes from the base 304. The alignment feature 306 may be configured to engage with external parts to secure the metal part 300 to the external parts.

[0085] Figure 4 illustrates an isometric view of the metal part 300. The fins 302 may include a complex and / or uniform geometry. For example, as shown, the fins 302 may be patterned to include attachment features 402. The attachment features 402 may be patterned as holes withinthe fins 302. The attachment features 402 may allow engagement with external parts, such as a part engaged with the alignment feature 306.

[0086] In some embodiments, the fin may be constructed with holes, perforations, slits, and / or other discontinuities to promote airflow and / or heat transfer through the fin. The geometry of these features may be optimized to balance structural rigidity with enhanced airflow or heat transfer. The discontinuities may be configured to be aligned through multiple fins, enabling direct flow paths through the fins, or may be offset to promote tortuous flow.

[0087] Figure 5 illustrates an isometric view of a metal part 500 similar to that depicted in Figures 1 and 2. The base and fins of metal part 500 have been configured with a concave cutout surface 502 to contour to a spherical surface or part.

[0088] Figure 6 illustrates a cutaway of the same isometric view of a metal part 500. Each fin 602 has an alternating series of small holes which enable greater airflow through the fins.Equivalents

[0089] The methods, systems, and devices discussed above are examples. Various configurations may omit, substitute, or add various procedures or components as appropriate. For instance, in alternative configurations, the methods may be performed in an order different from that described, and that various steps may be added, omitted, or combined. Also, features described with respect to certain configurations may be combined in various other configurations. Different aspects and elements of the configurations may be combined in a similar manner. Also, technology evolves and, thus, many of the elements are examples and do not limit the scope of the disclosure or claims.

[0090] Embodiments of the present disclosure, for example, are described above with reference to block diagrams and / or operational illustrations of methods, systems, and computer program products according to embodiments of the present disclosure. The functions / acts noted in the blocks may occur out of the order as shown in any flowchart. For example, two blocks shown in succession may in fact be executed substantially concurrent or the blocks may sometimes be executed in the reverse order, depending upon the functionality / acts involved. Additionally, or alternatively, not all of the blocks shown in any flowchart need to be performed and / or executed. For example, if a given flowchart has five blocks containing functions / acts, it may be the case that only three of the five blocks are performed and / or executed. In this example, any of the three of the five blocks may be performed and / or executed.

[0091] A statement that a value exceeds (or is more than) a first threshold value is equivalent to a statement that the value meets or exceeds a second threshold value that is slightly greater than the first threshold value, e.g., the second threshold value being one value higher than the first threshold value in the resolution of a relevant system. A statement that a value is less than (or is within) a first threshold value is equivalent to a statement that the value is less than or equal to a second threshold value that is slightly lower than the first threshold value, e.g., the second threshold value being one value lower than the first threshold value in the resolution of the relevant system.

[0092] Specific details are given in the description to provide a thorough understanding of example configurations (including implementations). However, configurations may be practiced without these specific details. This description provides example configurations only, and does not limit the scope, applicability, or configurations of the claims. Rather, the preceding description of the configurations will provide those skilled in the art with an enabling description for implementing described techniques. Various changes may be made in the function and arrangement of elements without departing from the spirit or scope of the disclosure.

[0093] Having described several example configurations, various modifications, alternative constructions, and equivalents may be used without departing from the spirit of the disclosure. For example, the above elements may be components of a larger system, wherein other rules may take precedence over or otherwise modify the application of various implementations or techniques of the present disclosure. Also, a number of steps may be undertaken before, during, or after the above elements are considered.

Claims

CLAIMSWhat is claimed is:

1. A method to produce a heat exchanger via laminated object manufacturing, the method comprising: patterning a plurality of metal sheets so that the metal sheets include a plurality of base regions and a plurality of fin regions, wherein at least one of the fin regions is separated from an adjacent fin region by a gap; and applying at least one of pressure or heat to bond the base regions into at least one solid structure and bond the fin regions into a plurality of fins while preserving the gaps between bonded fin regions, wherein each bonded fin region is attached to at least one bonded base region.

2. The method of claim 1 wherein each metal sheet comprises at least a portion of a base region.

3. The method of claim 2 wherein at least one fin has a thickness of a single metal sheet or less.

4. The method of claim 1 wherein each bonded fin region is attached at an angle offset to at least one bonded base region.

5. The method of claim 1 wherein the base regions comprise a channel to facilitate the flow of a coolant.

6. The method of claim 5 wherein the channel functions as a thermosiphon.

7. The method of claim 1 wherein each base region is adjacent to another base region to facilitate bonding.

8. The method of claim 1 further comprising depositing inhibitory material on at least one surface between a fin region and an adjacent fin region.

9. The method of claim 1 wherein at least one metal sheet comprises an alignment feature for allowing the heat exchanger to interface with an external part.

10. The method of claim 1 wherein at least one fin is connected to an adjacent fin by a bridging section.

11. The method of claim 1 wherein at least one fin comprises a uniform cross section.

12. The method of claim 1 wherein at least one fin comprises at least one of a wavy geometry or a notched geometry.

13. The method of claim 1 wherein at least one fin comprises a pattern of at least one hole or gap-43. A system for manufacturing a laminated object heat exchanger, the system comprising: a laminated object manufacturing device configured to pattern a plurality of metal sheets so that the metal sheets include a plurality of base regions and a plurality of fin regions, wherein at least one of the fin regions is separated from an adjacent fin region by a gap; and a pressor configured to apply at least one of pressure or heat to bond the base regions into at least one solid structure and bond the fin regions into a plurality of fins while preserving the gaps between bonded fin regions, wherein each bonded fin region is attached to at least one bonded base region.

15. The system of claim 14 wherein each metal sheet comprises at least a portion of a base region.

16. The system of claim 15 wherein at least one fin has a thickness of a single metal sheet or less.

17. The system of claim 14 wherein the base regions comprise a channel to facilitate the flow of a coolant.

18. The system of claim 14 wherein each base region is adjacent to another base region to facilitate bonding.

19. The system of claim 14 wherein at least one fin is connected to an adjacent fin by a bridging section.

20. The system of claim 14 wherein at least one fin comprises at least one of a wavy geometry or a notched geometry.

21. A heat exchanger formed via a laminated object manufacturing process, the process comprising: patterning a plurality of metal sheets so that the metal sheets include a plurality of base regions and a plurality of fin regions, wherein at least one of the fin regions is separated from an adjacent fin region by a gap; and applying at least one of pressure or heat to bond the base regions into at least one solid structure and bond the fin regions into a plurality of fins while preserving the gaps between bonded fin regions, wherein each bonded fin region is attached to at least one bonded base region.

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