Heat Exchanger Header Horn Structures With Removable AM Supports
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Solution Overview
Problem
Heat exchangers operating at elevated temperatures face reduced service life due to thermal stress, particularly at the interface between headers and the core, and internal support structures can complicate additive manufacturing and induce thermal stress during operation.
Innovation Solution
A heat exchanger design featuring integrated horns and a sacrificial support structure allows for additive manufacturing in a near-vertical orientation, reducing thermal stress and enabling efficient heat transfer while allowing for easy removal of support structures post-manufacture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If internal support structures are used during additive manufacturing, then complex geometries can be manufactured, but thermal stress increases during operation and service life decreases
Solution Approach 1:
The patent applies the extraction principle by designing support structures that can be selectively removed after manufacturing. The support structures are intentionally designed as separate, removable components that facilitate complex geometry manufacturing during additive processing, then can be extracted post-manufacturing to eliminate the source of thermal stress that would otherwise reduce service life during operation.
Solution Approach 2:
The patent implements the discarding principle by creating temporary support structures that serve their purpose during manufacturing and then are discarded afterward. These support structures are designed to be sacrificial - they enable the manufacturing of complex geometries but are intentionally removed after serving their structural function during the additive manufacturing process, thereby eliminating their harmful thermal stress effects during operational phase.
2Device complexity
If support structures remain intact during operation, then manufacturing complexity is reduced, but thermal stress increases and service life decreases
Solution Approach 1:
The patent applies extraction by designing support structures that are intentionally removed after manufacturing. This approach maintains relatively simple manufacturing processes while enabling complex geometries, and then extracts the support structures to eliminate thermal stress sources that would otherwise limit service life during operation.
Solution Approach 2:
The patent implements preliminary action by planning and designing the support structure removal process as part of the manufacturing workflow. The support structures are designed with predetermined removal methods and access paths, allowing for systematic extraction after manufacturing without requiring complex post-processing operations.
3Ease of manufacture
If traditional support structures are used, then manufacturing is simpler, but removal is difficult or impossible and thermal stress increases
Solution Approach 1:
The patent applies the extraction principle by designing support structures that can be selectively removed after manufacturing. This resolves the contradiction by enabling simple manufacturing processes while incorporating support structures that are intentionally designed for post-manufacturing extraction, thereby eliminating the thermal stress harmful factors that would persist if traditional permanent support structures remained in place.
Solution Approach 2:
The patent implements the disposable principle by creating temporary support structures that are inexpensive and intended for single-use during manufacturing. These support structures are designed to be sacrificial - they enable the manufacturing process but are intentionally removed afterward, serving their purpose temporarily and then being discarded to eliminate their harmful thermal stress effects during operation.
Data Source
AI summary
A heat exchanger header includes a primary fluid duct extending between a fluid port and a first branched region, a plurality of secondary fluid ducts fluidly connected to the primary fluid duct at the first branched region, wherein an overhang region is formed laterally between adjacent ones of the plurality of secondary fluid ducts, and wherein each of the plurality of secondary fluid ducts extends between the first branched region and a second branched region, a plurality of tertiary fluid ducts fluidly connected to each of the plurality of secondary fluid ducts at the second branched regions, a primary horn integrally formed with and extending from the overhang region, an at least one secondary horn integrally formed with and extending from one of the plurality of tertiary fluid ducts, and a sacrificial support structure extending between the primary horn and the at least one secondary horn.