Additively Manufactured Heat Exchanger With Interlaced Headers

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Solution Overview

Problem

Conventional manufacturing processes struggle to produce advanced heat exchangers with complex internal geometries, leading to sub-optimal designs due to manufacturability challenges.

Innovation Solution

An additively manufactured heat exchanger with interlaced headers and pathways, incorporating stiffening fins, exterior structural reinforcements, and self-supporting core structures, fabricated using laser powder bed fusion (PBF-L) to enable complex geometries and enhanced heat transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If conventional manufacturing processes are used, then manufacturing simplicity is maintained, but complex internal geometries cannot be produced

Engineering Contradiction:

Improveinternal geometry complexityVSAvoidmanufacturability

Core Design Contradiction:

Device complexityVSEase of manufacture

Solution Approach 1:

The patent replaces conventional mechanical manufacturing processes (machining, welding, assembly) with additive manufacturing technology. This substitution enables the direct fabrication of complex internal geometries including interlaced headers and pathways that would be impossible to achieve through traditional mechanical means, while maintaining manufacturing feasibility through automated additive processes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If heat transfer surface area is increased by adding fins, then heat transfer efficiency is improved, but structural complexity increases

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidstructural complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the heat transfer fin structures with the structural header and pathway components into an integrated additive manufacturing design. The headers and pathways are formed as single monolithic structures with built-in fin surfaces, eliminating the need for separate fin attachments or complex assembly operations while maximizing heat transfer surface area.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent utilizes three-dimensional interlaced geometries where headers and pathways are arranged in multiple spatial dimensions. This dimensional arrangement creates complex heat transfer surfaces through interwoven structures that would be impossible to achieve with traditional planar fin designs, significantly increasing heat transfer efficiency without proportional increases in manufacturing complexity.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Weight of moving object

If wall thickness is reduced, then weight is decreased, but structural integrity is compromised

Engineering Contradiction:

Improveheat exchanger weightVSAvoidstructural integrity

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent incorporates self-supporting core structures and internal stiffening features that are formed during the additive manufacturing process itself. These preliminary structural elements are built into the geometry before final assembly, providing internal reinforcement that allows thin-walled constructions to maintain structural integrity without requiring additional post-manufacturing strengthening operations.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent employs composite structural designs combining different material properties within the additive manufacturing process. By strategically placing materials with different characteristics during selective laser melting, the structure achieves optimized strength-to-weight ratio with thin walls, utilizing composite material distribution to maintain structural integrity while minimizing weight.

Inventive Principle:

Principle #40Composite materials

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution provides improved manufacturability, increased heat transfer efficiency, reduced wall thickness, and structural integrity through interlaced headers, internal stiffeners, and self-supporting geometries, overcoming conventional manufacturing limitations.

Implementation Method 1

laser powder bed fusion (PBF-L)

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

building up layers... by laser powder bed fusion (PBF-L)

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 3

heat is transferred from the hotter fluid to the colder fluid through a material of the fuel and oil pathways

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentUS20250334339A1Additively manufactured heat exchanger

Publication Date: 2025.10.30 HAMILTON SUNDSTRAND CORP

AI summary

An additively manufactured heat exchanger is provided and includes first and second inlet headers which are interlaced with one another, first and second outlet headers which are interlaced with one another and a core. The core is interposed between a pair of the first and second inlet headers and a pair of the first and second outlet headers. The core includes first pathways by which a first fluid flows from the first inlet header to the first outlet header and second pathways disposed in thermal communication with the first pathways and by which a second fluid flows from the second inlet header to the second outlet header.