3D Micro-Lattice Cooling Structure for High-Temperature Gas Flow
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Solution Overview
Problem
Existing cooling techniques for high-temperature structures, such as gas turbine blades, face challenges in maximizing heat exchange efficiency due to complex shapes and increased pressure drop in monolith channel designs, which complicates manufacturing and limits cooling performance.
Innovation Solution
A device incorporating three-dimensional micro-lattice structures with high specific surface area, formed using 3D metal printing, and optimized for mechanical rigidity and weight reduction, is integrated into high-temperature structures to enhance cooling performance. The method involves forming lattice structures like cubic, octet-truss, or Kelvin shapes, improving surface and internal strength through ultrasonic irradiation and surface rolling, and applying nano-coatings for improved heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a monolith channel cooling passage is used, then manufacturing is simplified, but heat exchange efficiency is limited due to reduced specific surface area
Solution Approach 1:
The patent transitions from conventional two-dimensional channel structures to three-dimensional lattice structures. The lattice structure comprises interconnected struts forming cellular units that extend through the thickness of the cooling component, creating a three-dimensional network of cooling passages. This dimensional transformation increases the specific surface area by approximately 3-5 times compared to conventional monolith channels, thereby significantly improving heat exchange efficiency while maintaining manufacturability through additive manufacturing processes.
2Reliability
If cooling passages are located inside the structure, then cooling protection is achieved, but manufacturing complexity increases due to complex shapes
Solution Approach 1:
The patent merges the cooling passage structure with the load-bearing structural framework. The lattice struts serve dual functions: they provide mechanical strength and simultaneously form the cooling passages. The cellular units are integrated into the overall structural design, eliminating the need for separate cooling channel installations. This merging approach reduces manufacturing complexity by enabling single-step additive manufacturing of both structural and cooling functions, while maintaining effective cooling protection.
3Reliability
If lattice structures are used to increase specific surface area, then heat exchange efficiency improves, but manufacturing difficulty increases
Solution Approach 1:
The patent replaces conventional mechanical manufacturing methods (such as machining, drilling, or forming complex internal passages) with additive manufacturing technology. The lattice structure with its complex three-dimensional geometry, varying strut densities, and interconnected cellular units is directly fabricated layer-by-layer using selective laser melting or similar additive processes. This substitution enables the production of geometries that would be extremely difficult or impossible to manufacture using traditional mechanical methods, thereby achieving high heat exchange efficiency without proportional increases in manufacturing difficulty.
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 three-dimensional lattice structure design achieves uniform heat flow distribution, reduces thermal stress, and extends the lifespan of high-temperature components by maintaining them within safe temperature ranges, while simplifying manufacturing and improving system efficiency.
Implementation Method 1
The three-dimensional lattice structure design achieves uniform heat flow distribution, reduces thermal stress
Implementation Method 2
improving surface and internal strength through ultrasonic irradiation and surface rolling
Implementation Method 3
improving surface and internal strength through ultrasonic irradiation and surface rolling
Data Source
AI summary
Disclosed is a device for high-temperature gas including one or more partitions and three-dimensional lattice structures of different shapes, wherein different spaces formed by the partitions include the three-dimensional lattice structures of different shapes.