Heat Exchanger Module Casting Impregnation
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Solution Overview
Problem
Current methods for manufacturing heat exchangers with multiple fluid circuits using different materials face limitations in achieving optimal thermal and mechanical performance, particularly due to complexities in assembly techniques and geometrical constraints, which restrict the use of alloys with good thermal properties and lead to thermal contact resistances and mechanical incompatibilities.
Innovation Solution
A process involving the realization of a metal envelope, metal tubes, and a three-dimensional metallic structure, where a metal or alloy with a lower fusion temperature is introduced and melted to impregnate the structure, allowing for a heat exchanger module with combined optimal thermal and mechanical properties through additive manufacturing and subsequent hot isostatic compression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If multiple different materials are used to optimize both mechanical strength and thermal properties, then thermal performance and mechanical strength are improved, but assembly complexity and manufacturing difficulty increase significantly
Solution Approach 1:
The patent combines multiple materials (metal envelope, three-dimensional metallic structure, and fusible metal) into a single integrated component through the casting process. The fusible metal is introduced in molten state and impregnates the three-dimensional structure, creating a unified heat exchanger module that eliminates the need for separate assembly steps and reduces manufacturing complexity.
Solution Approach 2:
The patent changes the physical state of the fusible metal from solid to liquid by heating above its melting point, enabling it to flow and impregnate the three-dimensional metallic structure. This parameter change (temperature increase) allows the molten metal to penetrate and bond with the structure, creating strong thermal and mechanical connections without complex assembly procedures.
2Shape
If complex geometries are manufactured using traditional machining and assembly methods, then functional requirements are met, but manufacturing time and production cost increase
Solution Approach 1:
The patent applies local quality by creating a three-dimensional metallic structure with specific local geometries that provide both mechanical support and thermal management functions. The fusible metal is then introduced to specifically impregnate these complex local structures, allowing the heat exchanger to achieve optimal thermal contact in critical areas without requiring complex assembly of multiple components throughout the entire structure.
3Temperature
If materials with optimal thermal properties are used, then heat exchange efficiency is improved, but mechanical strength may be compromised
Solution Approach 1:
The patent creates a composite material structure by combining a metal envelope with a three-dimensional metallic structure and impregnating it with fusible metal. This composite construction allows the envelope to provide mechanical strength while the fusible metal impregnation ensures optimal thermal contact and heat exchange efficiency throughout the three-dimensional structure, achieving both mechanical and thermal performance requirements simultaneously.
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 process simplifies the assembly of heat exchangers with complex geometries, enhances thermal and mechanical performance, and allows for high filling rates of materials with good thermal properties, overcoming the limitations of existing methods by integrating materials with differentiated properties effectively.
Implementation Method 1
heating of the sealed casing until the element(s) melt into at least one fusible metal or metal alloy
Implementation Method 2
with gravity impregnation of the three-dimensional structure and solidification of the tube(s)
Implementation Method 3
The various operations described above can be followed by a hot isostatic compression cycle
Data Source
Figure 1~1C
Figure 2~5
Figure 6
AI summary
The invention relates to a method for manufacturing a heat exchanger module with at least one fluid circuit, comprising a casting impregnation step of a three-dimensional structure with molten metal, thus ultimately yielding a heat exchanger module with optimal thermal and mechanical properties. The method combines one or more materials with differentiated properties, tubes, and fusible metal(s) or metal alloy(s) having good thermal characteristics, while the three-dimensional structure is adapted to mechanically reinforce the casing, and the casing itself exhibits good mechanical characteristics.