Heat Sink Monolithic Manifold Gap Thermal Stress Relief
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Solution Overview
Problem
Existing heat exchangers face issues with thermal gradients causing plastic strain and reduced service life due to temperature differences, and thermal short circuiting, which reduces their effectiveness.
Innovation Solution
A crossflow heat exchanger design featuring a monolithic manifold with a gap between the central and outer reservoirs, decoupling them thermally and using connection tabs as the primary thermal conduction path, formed either by machining or additive manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the central receiving reservoir and outer reservoirs are thermally coupled in existing heat exchangers, then heat transfer efficiency is improved, but thermal gradients cause plastic strain and reduced service life
Solution Approach 1:
The manifold is segmented into a central receiving reservoir and outer reservoirs that are thermally decoupled through the introduction of gaps. This segmentation prevents direct thermal coupling between reservoirs, eliminating thermal gradients that cause plastic strain while maintaining structural integrity through the monolithic construction.
Solution Approach 2:
The patent introduces gaps as intermediary elements between the central receiving reservoir and outer reservoirs. These gaps act as thermal barriers that prevent direct heat transfer between reservoirs, eliminating the thermal short circuiting effect while allowing the manifold to maintain its structural function.
2Ease of manufacture
If the manifold is formed as a single monolithic piece, then manufacturing complexity is reduced, but thermal short circuiting occurs between reservoirs
Solution Approach 1:
The monolithic manifold is segmented internally through the creation of gaps between reservoirs. This internal segmentation is achieved through machining or additive manufacturing processes, allowing the manifold to be manufactured as a single piece while preventing thermal short circuiting between the central receiving reservoir and outer reservoirs.
Solution Approach 2:
The patent changes the thermal conduction parameter by introducing gaps with specific dimensions (e.g., 0.005 to 0.05 inches) between reservoirs. This parameter change effectively reduces thermal conductivity between reservoirs to negligible levels while maintaining the structural continuity of the monolithic manifold.
3Loss of energy
If thermal gradients are present in the manifold, then heat transfer occurs between reservoirs, but plastic strain develops reducing service life
Solution Approach 1:
Gaps are introduced as intermediary thermal barriers between the central receiving reservoir and outer reservoirs. These gaps eliminate thermal gradients by preventing direct heat transfer between reservoirs at different temperatures, thereby eliminating the thermal stresses that cause plastic strain and reduce service life.
Solution Approach 2:
The patent converts the potential harm of thermal gradients into a benefit by using the gaps to deliberately block heat transfer paths. This prevents thermal short circuiting and eliminates the harmful thermal gradients that would otherwise cause plastic strain, while the gaps themselves become a beneficial feature for structural and thermal management.
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 design minimizes thermal gradients, reduces plastic strain, and prevents thermal short circuiting, thereby enhancing the service life and efficiency of the heat exchanger by maintaining effective heat transfer.
Implementation Method 1
thermal gradients causing plastic strain and reduced service life due to temperature differences
Implementation Method 2
connection tabs as the primary thermal conduction path
Implementation Method 3
Heat exchangers are devices built for transferring heat from one fluid to another
Data Source
AI summary
A crossflow heat exchanger includes an outer housing, an inlet that receives a hot fluid to be cooled and a monolithic manifold includes a central receiving reservoir and one or more outer reservoirs. The fluid received at the inlet passing into the central receiving reservoir. The exchanger also includes an outlet connected to the one or more outer reservoirs and tubes disposed within the outer housing that connect the central receiving reservoir and the one or more outer reservoirs. The monolithic manifold includes a gap formed between the central receiving reservoir and one or more outer reservoirs.