Heat Exchanger Core Channels for Turbulence and Powder Removal
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing additive manufacturing methods struggle to effectively remove residual powder from narrow, corrugated fluid flow channels in heat exchanger cores while maintaining turbulence for efficient heat exchange, as conventional methods fail to clear powder from such channels due to their complex shape.
Innovation Solution
Designing fluid flow channels with a straight axial path and varying geometry along the length to induce turbulence, using additive manufacturing, which allows for easy powder removal and maintains thermal efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If narrow, corrugated channels are used in heat exchanger cores, then heat exchange properties are improved due to turbulence, but powder removal becomes difficult
Solution Approach 1:
The channel is segmented into different geometric sections along its length - a first section with a first geometry and a second section with a second geometry. This segmentation allows each section to serve different functions: one section promotes turbulence for heat exchange while the other facilitates powder removal, resolving the contradiction between heat exchange performance and manufacturability
Solution Approach 2:
Different sections of the channel have different local geometries optimized for different purposes. The first section has geometry optimized for inducing turbulence and improving heat exchange, while the second section has geometry optimized for allowing fluid access and powder removal. This local differentiation resolves the contradiction by providing different properties in different locations within the same channel
2Ease of manufacture
If conventional vibration and rotation methods are used for powder removal, then simple channels can be cleaned, but narrow, corrugated channels cannot be effectively cleared
Solution Approach 1:
The channel geometry is locally optimized in different sections: the first section maintains complexity for heat exchange while the second section provides simplified access pathways that enable effective powder removal. This local differentiation allows the channel to achieve both turbulence generation and manufacturability
Solution Approach 2:
The second section of the channel acts as an intermediary pathway that connects the narrow, corrugated first section to the external cleaning fluid source. This intermediary section with its more accessible geometry enables cleaning fluid to reach and remove powder from the difficult-to-access first section, resolving the contradiction between geometric complexity and cleanability
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
The solution ensures effective powder removal and enhances thermal efficiency by inducing fluid turbulence without pressure drop, while accommodating 3D printing constraints.
Implementation Method 1
Thermal properties are improved by the introduction of turbulence in the flow channels
Implementation Method 2
Heat exchangers typically work by the transfer of heat between fluid flowing in parallel channels
Data Source
Figure 1A~1C
Figure 2A~2B
Figure 3
AI summary
A method of forming fluid flow channels for a heat exchanger core, the method comprising additively manufacturing the channels (1, 2) such that each channel includes a straight axial fluid path portion (A) extending from one end (30) of the channel to the other (40) and that the cross-sectional shape of the channel varies along its length to form curved contact surfaces for the fluid as it flows along the channel, while keeping the cross-sectional area constant along each channel.