Hybrid Heat Exchanger Header Construction for AM Angle Limits
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Solution Overview
Problem
Additive manufacturing techniques, such as 3D printing, impose geometrical constraints on heat exchanger configurations, limiting the maximum horizontal angle to about 45 degrees, which reduces the effectiveness of heat exchangers and requires additional supports that can be difficult to access and remove.
Innovation Solution
A hybrid construction method for heat exchangers is employed, where the heat exchanger body is formed via additive manufacturing, and the inlet and outlet manifolds are formed via subtractive manufacturing processes like machining or milling, allowing for more complex geometries and reduced flow lengths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If additive manufacturing processes are used to form the heat exchanger body, then manufacturing flexibility and complex geometry capability are improved, but geometrical constraints (maximum horizontal angle of about 45 degrees) and longer transition lengths worsen
Solution Approach 1:
The heat exchanger is divided into two distinct parts: the heat exchanger body formed by additive manufacturing and the manifolds formed by subtractive manufacturing. This segmentation allows each part to be optimized for its respective manufacturing process, with the body achieving complex geometries through 3D printing and the manifolds achieving precise angular transitions through machining.
Solution Approach 2:
The patent combines two different manufacturing approaches (additive and subtractive) to create a hybrid construction. The heat exchanger body utilizes additive manufacturing for its complex three-dimensional tube arrangements, while the manifolds utilize subtractive manufacturing for precise angular geometry, merging the advantages of both processes.
2Ease of manufacture
If additive manufacturing is used, then manufacturing capability is improved, but additional supports are required that are difficult to access and remove
Solution Approach 1:
By separating the heat exchanger body and manifolds into distinct components manufactured by different processes, the patent eliminates the need for internal support structures within the manifolds. The subtractive manufacturing of manifolds from solid blocks allows for clean, support-free geometry, while the additive body is manufactured separately and assembled.
3Manufacturing precision
If subtractive manufacturing is used for manifolds, then geometric precision and compact design are improved, but manufacturing complexity increases
Solution Approach 1:
The patent segments the manufacturing process so that only the manifolds require precision subtractive manufacturing, while the heat exchanger body uses additive manufacturing. This division limits the complexity of subtractive operations to specific components rather than the entire heat exchanger assembly.
Solution Approach 2:
The hybrid manufacturing approach merges additive and subtractive processes, allowing each method to be applied where it provides the greatest benefit. Additive manufacturing handles the complex three-dimensional tube structures, while subtractive manufacturing handles the precision angular transitions in manifolds, optimizing the overall manufacturing strategy.
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 hybrid construction method enables a more compact heat exchanger design or increased tube length for enhanced heat transfer capability, while avoiding the limitations of purely additive manufacturing.
Implementation Method 1
a heat exchanger body (12) having a plurality of body tubes (14)... configured to direct a flow of fluid (22) through the heat exchanger body (12)... A flow of air (24) is directed across the body tubes (14)... and the flow of fluid (22) is cooled, or alternatively heated, via exchange of thermal energy between the flow of air (24) and the flow of fluid (22)
Data Source
Figure 1
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Figure 3
AI summary
A heat exchanger (10) includes a heat exchanger body (12) having a plurality of heat exchanger tubes (14), an inlet manifold connected to the heat exchanger body and configured to distribute a flow of fluid from a fluid inlet (28) of the inlet manifold (30) to the plurality of heat exchanger tubes (14), and an outlet manifold (40) connected to the heat exchanger body (12) and configured to collect the flow of fluid from the plurality of heat exchanger tubes (14) and direct the flow of fluid through a fluid outlet (42). The heat exchanger body (12) is formed via one or more additive manufacturing processes, and at least one of the inlet manifold (30) and the outlet manifold (40) is formed via one or more subtractive manufacturing processes.