Modular Heat Exchanger Cores with Mechanical Face Seals

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Solution Overview

Problem

Additive manufacturing of heat exchangers faces challenges such as limited component size, assembly complexity, and the inability to weld or braise aluminum alloys commonly used in this process, particularly in harsh environments.

Innovation Solution

A modular heat exchanger design featuring a structural support with mating interfaces that mechanically couple multiple heat exchanger cores, allowing for efficient assembly and fluid coupling, while utilizing additive manufacturing for single-piece core and support construction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If additive manufacturing is used to make heat exchangers, then manufacturing flexibility and design freedom are improved, but component size is limited and assembly complexity increases

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidassembly complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The heat exchanger is divided into multiple additive-manufactured components (cores, distribution headers, support structures) that can be manufactured separately and then assembled. This segmentation allows each component to be optimized for additive manufacturing while maintaining overall system functionality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple functional elements are combined into single additive-manufactured components. For example, distribution headers integrate fluid distribution channels and structural support functions, reducing the number of separate parts needed and simplifying assembly.

Inventive Principle:

Principle #5Merging (Combining)

2Length of stationary object

If heat exchangers are manufactured as multiple sections using additive manufacturing, then larger heat exchangers can be created, but joint reliability deteriorates due to inability to weld or braise aluminum alloys

Engineering Contradiction:

Improveheat exchanger sizeVSAvoidjoint reliability

Core Design Contradiction:

Length of stationary objectVSReliability

Solution Approach 1:

Joining features such as threaded holes, recesses, and mating surfaces are built into the additive-manufactured components during the manufacturing process itself. This preliminary incorporation of joining features eliminates the need for post-manufacturing welding or brazing, ensuring reliable connections while maintaining the benefits of additive manufacturing.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If traditional manufacturing methods are used, then joint reliability is improved through welding and brazing, but manufacturing flexibility and design freedom are reduced

Engineering Contradiction:

Improvejoint reliabilityVSAvoidmanufacturing flexibility

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Traditional thermal joining methods (welding and brazing) are replaced with mechanical joining methods (threaded fasteners, interference fits, bayonet couplings) that are integrated into the additive-manufactured components. This substitution maintains joint reliability while enabling the manufacturing flexibility and design freedom of additive manufacturing.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS20250075986A1Heat exchangers with modular cores and methods of making the same

Publication Date: 2025.03.06 MEGGITT AEROSPACE

AI summary

Heat exchangers and methods of making heat exchangers are discussed herein. The heat exchangers are unique in that they comprise a plurality of heat exchanger cores mechanically coupled to a structural frame that may be comprised by a distribution header to form an array of heat exchanger cores. In preferred embodiments, each core has one or more mounting interfaces that includes at least one input port and output port and is coupled to the distribution header in a removeable configuration via a face seal. In preferred embodiments, the heat exchanger cores are cantilevered from the structural support or distribution header.