Segmented Heat Exchanger Core to Prevent Flow Path Mixing

Solution Overview

Problem

Existing heat exchangers manufactured using additive manufacturing face limitations in size increase due to equipment constraints and prolonged manufacturing times, with potential issues of positional deviation and dimensional errors leading to fluid mixing in flow paths.

Innovation Solution

A heat exchanger design comprising a core portion with divided units, each having first and second refrigerant flow paths, joined via positioning protrusions and holes to prevent fluid mixing, allowing for easy size expansion without quality deterioration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a heat exchanger is manufactured by additive manufacturing to form a complicated three-dimensional shape, then manufacturing flexibility and design freedom are improved, but manufacturing time increases significantly and size is limited by equipment constraints

Engineering Contradiction:

Improvedesign freedomVSAvoidmanufacturing time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The heat exchanger is divided into multiple modular units that can be manufactured separately through additive manufacturing and then assembled together. This segmentation allows each unit to be produced within reasonable manufacturing time limits while the final assembled heat exchanger achieves the desired large size and complicated three-dimensional shape.

Inventive Principle:

Principle #1Segmentation

2Productivity

If a heat exchanger is divided into multiple units for manufacturing, then manufacturing time and equipment limitations are reduced, but positional deviation and dimensional errors may cause cooling water and air flow paths to communicate, resulting in fluid mixing

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidflow path separation

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

Positioning protrusions and positioning holes are provided on the outer surfaces of the units before assembly. These positioning features are manufactured in advance with precise dimensions, ensuring that when units are assembled, they align correctly without positional deviation that could cause flow path communication between cooling water and air channels.

Inventive Principle:

Principle #10Preliminary action

3Volume of stationary object

If the heat exchanger size is increased using additive manufacturing, then heat exchange capacity is improved, but manufacturing time increases and equipment constraints are exceeded

Engineering Contradiction:

Improveheat exchanger sizeVSAvoidmanufacturing time

Core Design Contradiction:

Volume of stationary objectVSLoss of time

Solution Approach 1:

The heat exchanger is divided into multiple modular units that can be manufactured separately through additive manufacturing and then assembled together. This segmentation allows each unit to be produced within reasonable manufacturing time limits while the final assembled heat exchanger achieves the desired large size and complicated three-dimensional shape.

Inventive Principle:

Principle #1Segmentation

4Ease of manufacture

If multiple units are joined to form the heat exchanger, then manufacturing flexibility is improved, but positional deviation may occur during joining

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidpositioning accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

Positioning protrusions and positioning holes are provided on the outer surfaces of the units before assembly. These positioning features are manufactured in advance with precise dimensions, ensuring that when units are assembled, they align correctly without positional deviation that could cause flow path communication between cooling water and air channels.

Inventive Principle:

Principle #10Preliminary action

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

Enables larger heat exchanger production without fluid mixing, maintaining quality by using additive manufacturing to form units and joining them with precise alignment, reducing manufacturing time and equipment limitations.

Implementation Method 1

a first refrigerant flow path (5) provided in the core portion (3) and configured to allow cooling water to flow therethrough; and a second refrigerant flow path (7) provided in the core portion (3) and configured to allow air to flow therethrough, in which in the core portion (3), the cooling water flowing through the first refrigerant flow path (5) and the air flowing through the second refrigerant flow path (7) exchange heat via a partition wall (54)

Methodology Applied

Scientific EffectPhysical separation: Physical Containment

Implementation Method 2

forming a plurality of the units (40) by additive manufacturing a material

Methodology Applied

Scientific EffectAdditive manufacturing: 3D Printing

Implementation Method 3

joining the plurality of units (40) to form the core portion (3)

Methodology Applied

Scientific EffectMechanical joining: Mechanical Fastener

Data Source

PatentUS12578148B2Heat exchanger and method for manufacturing the same

Publication Date: 2026.03.17 HONDA MOTOR CO LTD

AI summary

A heat exchanger includes: a core portion; a first refrigerant flow path; and a second refrigerant flow path as defined herein, the first refrigerant flow path includes a plurality of first main flow paths as defined herein, the second refrigerant flow path includes a plurality of second main flow paths extending in the first direction and arranged in the second direction, the plurality of second main flow paths arranged in the second direction are formed by being surrounded by the partition wall constituting the first main flow path, and are provided in each of a plurality of rows arranged in the third direction, the core portion is formed by joining a plurality of units, and the first main flow path of each of the plurality of units is a region closed by the partition wall in a cross section viewed from the first direction.