Additive Heat Exchanger Substrates for Thin-Wall Flow Channels

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Solution Overview

Problem

Conventional heat exchanger manufacturing methods, such as etching and stamping, limit shape flexibility and result in heavy, difficult-to-inspect components with thick walls and limited aspect ratios, making them unsuitable for high-pressure applications and efficient heat transfer.

Innovation Solution

The method involves additive manufacturing to create substrates with integrally formed partial and whole fluid flow channels and fins, allowing for layer-wise assembly and inspection before final assembly, enabling lighter weight, customizable designs with reduced wall thickness and enhanced heat transfer capabilities.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional etching or stamping methods are used to manufacture heat exchangers, then manufacturing simplicity is maintained, but the heat exchangers result in heavy weight, thick walls, and limited design flexibility

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidheat exchanger weight

Core Design Contradiction:

Ease of manufactureVSWeight of moving object

Solution Approach 1:

The heat exchanger is divided into multiple plates, each containing flow passages. These segmented plates are stacked and sealed together to form the complete heat exchanger assembly, allowing for weight reduction while maintaining structural integrity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The manufacturing process transitions from conventional etching/stamping to additive manufacturing, fundamentally changing the production parameters to enable complex geometries, thinner walls, and reduced weight while maintaining manufacturing feasibility

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If conventional etching or stamping methods are used, then manufacturing process simplicity is preserved, but design flexibility and aspect ratios are severely limited

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidflow passage shape flexibility

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The manufacturing methodology is changed from subtractive (etching/stamping) to additive manufacturing, enabling complex three-dimensional flow passage geometries, variable cross-sections, and high aspect ratios that cannot be achieved with conventional methods

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

Additive manufacturing enables the creation of truly three-dimensional flow passages within the plates, moving beyond the limited two-dimensional patterns achievable through etching and stamping, allowing for optimized heat transfer paths and compact designs

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Ease of manufacture

If conventional manufacturing methods are used, then production simplicity is maintained, but wall thickness is increased making inspection difficult

Engineering Contradiction:

Improveproduction simplicityVSAvoiddefect inspection difficulty

Core Design Contradiction:

Ease of manufactureVSDifficulty of detecting and measuring

Solution Approach 1:

Dividing the heat exchanger into separate stackable plates allows each plate to be manufactured and inspected individually before final assembly, making defect detection more accessible and manageable

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Additive manufacturing produces thinner, more uniform walls compared to conventional methods, reducing the difficulty of inspection while maintaining structural integrity and pressure containment capabilities

Inventive Principle:

Principle #35Parameter changes

4Ease of manufacture

If conventional manufacturing methods are used, then manufacturing simplicity is maintained, but heat transfer efficiency is reduced due to thick walls

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidheat transfer efficiency

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The transition to additive manufacturing enables the production of thinner walls with optimized thickness distributions, reducing thermal resistance and improving heat transfer efficiency while maintaining manufacturing capability

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

Additive manufacturing allows for optimized curved and complex flow passage geometries that enhance fluid mixing and heat transfer coefficients, improving overall heat transfer efficiency compared to conventional straight-channel designs

Inventive Principle:

Principle #14Spheroidality (Curvature)

Data Source

PatentUS11686537B2Heat exchangers and methods of manufacturing the same

Publication Date: 2023.06.27 GENERAL ELECTRIC CO

AI summary

A method of manufacturing a heat exchanger is provided. The method includes forming a first substrate by additively manufacturing a body defining a first outer surface and a second outer surface opposite the first outer surface, a first partial fluid flow channel formed within the first outer surface, a second partial fluid flow channel formed within the second outer surface, and at least one internal fluid flow channel completely formed within the body, and coupling the first substrate to a second substrate including a partial fluid flow channel formed within a surface of the second substrate such that the first partial fluid flow channel of the first substrate and the partial fluid flow channel of the second substrate combine to form a combined fluid flow channel.