Monolithic Bicontinuous Heat Exchanger Core for Additive Manufacturing

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Solution Overview

Problem

Conventional heat exchanger core designs and manufacturing methods are limited by high fabrication and maintenance costs, low yields, and incompatibility with additive manufacturing due to complex geometries and overhanging surfaces.

Innovation Solution

The development of monolithic bi-continuous core structures with minimal or zero mean Gaussian curvature, allowing for efficient fabrication using additive manufacturing techniques, which creates two or more independent labyrinths for enhanced heat transfer and flexibility in design.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If conventional shell-in-tube or plate-and-fin core designs are used, then heat transfer surface area can be achieved, but extensive brazing and welding are required to isolate fluid paths and seal interfaces, increasing fabrication complexity and cost

Engineering Contradiction:

Improveheat transfer surface areaVSAvoidfabrication complexity

Core Design Contradiction:

Quantity of substanceVSDevice complexity

Solution Approach 1:

The patent merges multiple separate components (shells, tubes, plates, fins, and seals) into a single monolithic bi-continuous structure fabricated by additive manufacturing. This integration eliminates the need for brazing and welding operations while maintaining heat transfer surface area, directly resolving the contradiction between achieving sufficient heat transfer area and reducing fabrication complexity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The monolithic bi-continuous structure serves multiple functions simultaneously: it provides heat transfer surface area, isolates fluid paths, seals interfaces, and structural support all in one component. This multi-functionality eliminates the need for separate brazing and welding operations to achieve these functions, reducing fabrication complexity while maintaining heat transfer performance

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Shape

If conventional core designs with 90 degree angles and overhanging surfaces are used, then complex geometries can be achieved, but these are not well suited for additive manufacturing processes

Engineering Contradiction:

Improvegeometric complexityVSAvoidadditive manufacturing compatibility

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

The patent employs unit cell configurations with minimal or zero mean Gaussian curvature, avoiding sharp 90-degree angles and overhanging surfaces that are problematic for additive manufacturing. The curved, self-supporting geometries are naturally compatible with AM processes while still achieving the required complex bi-continuous structure, resolving the contradiction between geometric complexity and manufacturability

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The patent changes the geometric parameters of the unit cells to ensure minimal or zero mean Gaussian curvature, making the structures self-supporting during additive manufacturing. This parameter optimization allows complex bi-continuous geometries to be fabricated without overhangs, resolving the contradiction between achieving complex shapes and ensuring AM compatibility

Inventive Principle:

Principle #35Parameter changes

3Reliability

If conventional brazed or welded joint methods are used, then fluid path isolation can be achieved, but fabrication and maintenance costs increase and yields decrease

Engineering Contradiction:

Improvefluid path isolationVSAvoidfabrication efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent combines fluid path isolation, sealing, and structural functions into a single monolithic structure fabricated by additive manufacturing. This eliminates multiple brazing and welding operations, improving fabrication efficiency and yields while maintaining reliable fluid path isolation through the continuous monolithic material structure

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The additive manufacturing process itself creates the fluid path isolation and sealing features during fabrication, without requiring subsequent brazing or welding operations. The monolithic structure is self-sufficient, achieving fluid path isolation inherently through its continuous material structure, which improves fabrication efficiency and reduces maintenance costs

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS11181329B2Monolithic bicontinuous labyrinth structures and methods for their manufacture

Publication Date: 2021.11.23 TITAN TENSOR LLC

AI summary

A heat exchanger includes a core comprising a single piece continuous boundary having a first surface defining a first labyrinth, and an opposing second surface defining a second labyrinth; a first inlet manifold connected to the first labyrinth and configured to supply a first fluid to the first labyrinth; and a second inlet manifold connected to the second labyrinth and configured to supply a second fluid to the second labyrinth; wherein the core comprises a plurality of identical three dimensional unit cell structures replicated in three orthogonal spatial dimensions.