Cross Flow Ceramic Heat Exchanger Additive Manufacturing

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Solution Overview

Problem

Conventional heat exchanger technologies face challenges in achieving high-temperature capabilities beyond the limits of conventional metals and suffer from poor thermal conductivity and high manufacturing costs in ceramic heat exchanger development.

Innovation Solution

The development of a high-temperature plate-fin ceramic heat exchanger using a layer-by-layer additive manufacturing process, specifically Laminated Object Manufacturing (LOM), which incorporates axial and transverse fins formed from ceramic materials to create a serpentine flow path that enhances thermal conductivity and structural support, allowing for efficient heat transfer and reduced manufacturing difficulties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If ceramic materials are used for high-temperature heat exchanger, then temperature capability is improved, but thermal conductivity deteriorates

Engineering Contradiction:

Improvetemperature capabilityVSAvoidthermal conductivity

Core Design Contradiction:

TemperatureVSLoss of energy

Solution Approach 1:

The patent uses ceramic matrix composite materials that combine ceramic base material with reinforcing fibers or particles. This composite structure maintains the high-temperature resistance of ceramics while improving thermal conductivity through the composite architecture, resolving the contradiction between temperature capability and thermal conductivity.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent implements localized quality variations in the ceramic structure, such as creating regions with different ceramic compositions or densities. High thermal conductivity regions are strategically placed in heat transfer paths, while high-temperature resistant regions are placed in extreme temperature zones, optimizing both properties where needed.

Inventive Principle:

Principle #3Local quality

2Ease of manufacture

If conventional manufacturing processes are used for ceramic heat exchanger, then manufacturing simplicity is maintained, but manufacturing cost increases

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidmanufacturing cost

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent divides the heat exchanger into modular segments or layers that can be manufactured separately using simpler processes and then assembled. This segmentation allows each module to be produced more efficiently and economically, reducing overall manufacturing cost while maintaining simplicity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent combines multiple manufacturing steps or operations into integrated processes. For example, combining forming and sintering operations, or integrating fin structures directly into the manufacturing process rather than adding them separately, reduces the number of steps and lowers manufacturing costs.

Inventive Principle:

Principle #5Merging (Combining)

3Loss of energy

If complex fin structures are used to enhance heat transfer, then heat transfer efficiency is improved, but manufacturing difficulty increases

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidmanufacturing difficulty

Core Design Contradiction:

Loss of energyVSEase of manufacture

Solution Approach 1:

The patent incorporates fin structures and other heat transfer features directly into the green body or mold during the initial forming stage, before sintering. This preliminary action allows complex geometries to be created without requiring difficult post-sintering manufacturing operations, maintaining manufacturing ease while achieving high heat transfer efficiency.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent optimizes fin structure parameters such as thickness, spacing, and height to achieve efficient heat transfer with simpler geometries. By carefully selecting parameters within certain ranges, the patent maintains high heat transfer performance while using manufacturing-friendly designs that are easier to produce.

Inventive Principle:

Principle #35Parameter changes

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

This approach enables the creation of high-temperature heat exchangers with improved thermal performance and reduced manufacturing costs, overcoming the limitations of conventional materials and processes by utilizing ceramic materials and optimized fin designs for enhanced heat transfer and structural integrity.

Implementation Method 1

incorporates axial and transverse fins formed from ceramic materials to create a serpentine flow path that enhances thermal conductivity and structural support, allowing for efficient heat transfer

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

allowing for inlet temperatures up to 900° C. However, ceramic heat exchanger development has been limited in past years due to poor thermal conductivity

Methodology Applied

Scientific EffectThermal resistance: Thermal Insulation

Data Source

PatentUS10646969B2Cross flow ceramic heat exchanger and method for manufacturing

Publication Date: 2020.05.12 HAMILTON SUNDSTRAND CORP

AI summary

A heat exchanger includes a first additively manufactured layer including axial fins extending in a first direction and transverse fins extending in a second direction transverse to the first direction, the first layer defining a flow path in the first direction. The heat exchanger also includes a second additively manufactured layer including axial fins extending in the second and transverse fins extending in the first direction, the second layer defining a second flow path in the second direction.