Additive Manufactured Heat Exchange Core Connection
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Solution Overview
Problem
Additive manufacturing of heat exchange cores using a powder bed method faces challenges with insufficient melting at the intersections of thin wall portions and larger volume parts, leading to manufacturing defects such as fluid leakage due to poor formation.
Innovation Solution
Incorporating a first connection portion with a width greater than the thickness of the wall portions, connected to the base portion, to enhance heat absorption and prevent insufficient melting during the additive manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If thin wall portions are used to reduce heat transfer distance, then heat transfer efficiency is improved, but insufficient melting occurs at the intersection between the thin wall portion and larger volume parts
Solution Approach 1:
The patent applies local quality by making the connection portion wider than the wall portions it connects. This creates a localized variation in geometry where the connection portion has greater width to improve heat absorption during additive manufacturing, while the wall portions maintain thin dimensions for optimal heat transfer efficiency. This resolves the contradiction by allowing thin walls for heat transfer while providing localized geometric enhancement for manufacturing completeness.
2Device complexity
If the connection portion has the same width as the wall portions, then the structure is simple, but insufficient melting occurs leading to manufacturing defects
Solution Approach 1:
The connection portion is designed with a width greater than the wall portions it connects, creating a localized geometric variation that improves heat absorption during additive manufacturing. This local modification ensures complete melting and proper formation at critical intersection points without requiring complex overall structural changes, thus maintaining relative simplicity while improving reliability.
3Manufacturing precision
If the connection portion is made wider, then heat absorption is improved preventing insufficient melting, but the overall device complexity increases
Solution Approach 1:
The patent implements local quality by widening only the connection portions where melting completeness is critical, rather than increasing the dimensions of all components. This localized geometric modification improves manufacturing precision at specific locations while minimizing the overall increase in device complexity, as the wall portions and other components maintain their original thin-dimension design.
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 configuration improves the quality of the heat exchange core by reducing the likelihood of insufficient melting and associated defects, ensuring better formation and functionality of the heat exchange core.
Implementation Method 1
a three-dimensional additive manufactured object is formed by repeatedly melting and solidifying a metal powder used as a raw material powder layered in layers, by irradiating the metal powder with an energy beam
Implementation Method 2
irradiating the metal powder with an energy beam such as a light beam or an electron beam
Data Source
AI summary
An additive manufactured object according to at least one embodiment of the present disclosure includes a first base portion made of a metal, and a plurality of wall portions each having a thickness thinner than the first base portion and provided upright on the first base portion so as to be aligned in a wall thickness direction. A first end portion of each of the wall portions is connected to the first base portion via a first connection portion having a width greater than the thickness of each of the wall portions in the wall thickness direction.