Minimal Surface Heat Exchanger Core for Thermal Stress Relief
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Solution Overview
Problem
Traditional heat exchanger designs using straight geometry building blocks result in low compliance, leading to mismatched strain and high stresses under nonlinear thermal gradients, limiting heat transfer, increasing pressure loss, and vibration response.
Innovation Solution
A monolithic heat exchanger core comprising three-dimensional unit cells arranged along orthogonal axes with independently variable dimensions, utilizing scaling coefficients for implicit surface approximations to create asymmetrical geometries that enhance heat transfer and structural compliance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional straight geometry building blocks are used to design heat exchangers, then ease of manufacturing is improved, but structural compliance and heat transfer performance deteriorate under nonlinear thermal gradients
Solution Approach 1:
The patent applies asymmetry by transitioning from traditional symmetric straight geometry building blocks to asymmetric curved minimal surface geometries. The minimal surfaces are defined by implicit equations with scaling coefficients that create non-uniform, asymmetric shapes adapted to nonlinear thermal gradients, enabling the structure to comply with thermal deformations while maintaining manufacturing feasibility through modern additive manufacturing techniques
Solution Approach 2:
The patent employs parameter changes by introducing scaling coefficients (a, b, c, d, e, f) into the implicit surface equations that define the minimal surfaces. These parameters allow continuous adjustment of the geometry to match specific thermal gradient conditions, enabling the heat exchanger to adapt its structural compliance to nonlinear thermal environments while being manufactured as a monolithic integrated component
2Device complexity
If traditional straight geometry heat exchangers are used, then device simplicity is maintained, but heat transfer rates and pressure loss performance deteriorate
Solution Approach 1:
The patent applies curvature by replacing straight geometry with minimal surfaces that exhibit continuous curvature in three dimensions. The implicit surface equations generate smoothly curved geometries that maximize surface area for heat transfer while maintaining structural integrity, enabling superior heat transfer rates and pressure loss characteristics compared to traditional straight-lined constructions
Solution Approach 2:
The patent merges multiple functions into a single monolithic heat exchanger core by integrating the heat transfer surfaces, structural support, and thermal compliance features into one continuously manufactured component. This eliminates the need for separate assembly of multiple parts while achieving enhanced heat transfer performance through the optimized minimal surface geometry
3Productivity
If non-symmetrical unit cell dimensions are implemented, then heat transfer optimization and thermal stress reduction are improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies local quality by allowing different scaling coefficients to be applied in different spatial directions (x, y, z axes) of the unit cells. This creates locally optimized geometries where the surface area and curvature are tailored to the specific thermal and mechanical requirements of each region, maximizing heat transfer efficiency and thermal stress management while maintaining a regular repeating unit cell pattern that simplifies manufacturing
Data Source
AI summary
A monolithic core for a heat exchanger comprises a plurality of three-dimensional unit cells arranged along three orthogonal axes of the core, the three orthogonal axes comprising a first axis, a second axis, and a third axis. Each of the plurality of unit cells has a first dimension comprising an axial extent along the first axis, a second dimension comprising an axial extent along the second axis, and a third dimension comprising an axial extent along the third axis. For at least one unit cell of the plurality of unit cells, the first dimension is not equal to the second dimension.