Heat Exchanger Tubes with 3D Internal Flow Features
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Solution Overview
Problem
Existing heat exchanger tubes with two-dimensional flow features are limited in improving heat transfer and hydraulic performance, especially at bends or turns, and are difficult to fabricate with more complex geometries.
Innovation Solution
A support form with a lattice section and a solid section is used to create three-dimensional flow features through an additive manufacturing process, allowing for the deposition of a material to form a heat exchanger tube with internal flow features that extend from the sidewall, facilitating improved heat transfer and hydraulic performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If two-dimensional flow features are used in heat exchanger tubes, then manufacturing is simpler, but heat transfer and hydraulic performance improvement is limited
Solution Approach 1:
The patent transitions from two-dimensional flow features to three-dimensional flow features within the heat exchanger tube. The internal flow features include three-dimensional structures such as protrusions, recesses, and complex geometries that extend radially into the fluid passage, creating multi-dimensional flow manipulation capabilities that significantly enhance heat transfer and hydraulic performance compared to conventional two-dimensional features.
2Reliability
If complex three-dimensional flow features are fabricated, then heat transfer and hydraulic performance is improved, but manufacturing difficulty increases
Solution Approach 1:
The patent employs additive manufacturing technology to fabricate complex three-dimensional flow features that would be difficult or impossible to create using conventional manufacturing methods. This manufacturing approach enables the creation of intricate internal geometries including varying cross-sections, non-uniform distributions, and complex spatial arrangements of flow features throughout the heat exchanger tube.
3Reliability
If complex geometries are used for flow features, then heat transfer performance is improved, but fabrication difficulty increases
Solution Approach 1:
The patent employs additive manufacturing technology to fabricate complex three-dimensional flow features that would be difficult or impossible to create using conventional manufacturing methods. This manufacturing approach enables the creation of intricate internal geometries including varying cross-sections, non-uniform distributions, and complex spatial arrangements of flow features throughout the heat exchanger tube.
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 method enables the fabrication of heat exchanger tubes with three-dimensional internal flow features, enhancing heat transfer and hydraulic capabilities compared to two-dimensional designs.
Implementation Method 1
A support form with a lattice section and a solid section is used to create three-dimensional flow features through an additive manufacturing process
Implementation Method 2
allowing for the deposition of a material to form a heat exchanger tube with internal flow features
Implementation Method 3
Heat exchanger tubes carrying a fluid having a thermal energy content
Implementation Method 4
heat exchanger tubes may be used in heat exchangers, electrical machines, motors, and/or generators
Data Source
AI summary
A support form defining a longitudinal axis is provided. The support form includes a first section, a second substantially solid section, and at least one flow feature form. The first section includes a plurality of unit cells of a first material joined together to form a lattice. The second section includes a second material and surrounds the first section. The at least one flow feature form is defined in the second section and is configured to generate a flow feature on a heat exchanger tube formed by plating the support form.