Multi-Layer Heat Exchanger Ribs for Lower Pressure Drop

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Solution Overview

Problem

Traditional heat exchangers for liquid-cooled motor controllers, made by vacuum brazing, often result in warped surfaces and reduced thermal performance due to uncontrolled process parameters, leading to higher pressure drops and manufacturing challenges.

Innovation Solution

A heat exchanger design featuring opposed plates with additive manufacturing ribs that include slits to define a flow path, where each rib is formed from aligned layers, allowing for improved thermal performance and manufacturability, with options for rectangular slit arrays and alignment configurations to optimize pressure drop and heat transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If vacuum brazing process is used to manufacture heat exchangers, then heat exchangers can be produced, but warped surfaces and melted/deformed fin cores occur resulting in higher pressure drops and reduced thermal performance

Engineering Contradiction:

ImprovemanufacturabilityVSAvoidsurface warping and fin core deformation

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent changes the manufacturing method from vacuum brazing to additive manufacturing, fundamentally altering the process parameters to eliminate thermal exposure that causes warping and deformation. The additive manufacturing process builds parts layer-by-layer without melting the final structure, preserving geometric precision.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the thermal field (vacuum brazing) with a mechanical field (additive manufacturing layer deposition). This substitution eliminates the harmful thermal effects while achieving the same manufacturing goal of creating heat exchanger components with complex geometries.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If vacuum brazing process parameters are not well controlled, then manufacturing flexibility is maintained, but thermal performance decreases and pressure drops increase

Engineering Contradiction:

Improveprocess parameter flexibilityVSAvoidthermal performance

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent changes from controlling thermal parameters in vacuum brazing to controlling geometric parameters in additive manufacturing. This allows for design flexibility in rib configurations, slit patterns, and flow channel geometries while ensuring consistent thermal performance through precise digital modeling and fabrication.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses computer-aided design and simulation to optimize the heat exchanger geometry before manufacturing. This preliminary digital prototyping allows for testing and optimization of flow paths and heat transfer surfaces without physical trials, ensuring optimal thermal performance before fabrication.

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If additive manufacturing layers are used to form ribs, then manufacturing precision and design flexibility improve, but process complexity increases

Engineering Contradiction:

Improverib geometry precisionVSAvoidadditive manufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent segments the heat exchanger into modular components (plates and ribs) that can be manufactured separately using additive manufacturing and then assembled. This segmentation simplifies the manufacturing process by allowing each component to be optimized independently while reducing overall process complexity through modular assembly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs a universal additive manufacturing process that can create various rib configurations, slit patterns, and geometries using the same equipment and material system. This multi-functionality reduces process complexity by eliminating the need for different manufacturing lines for different heat exchanger designs.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 solution enhances thermal performance and manufacturability by reducing pressure drops and improving heat transfer, while allowing for flexible design configurations to suit specific applications.

Implementation Method 1

cooling of the cold plate body by circulation of fluid through the cooling channels and heat exchanger

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 2

heat transfer

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS11585612B2Heat exchangers with multi-layer structures

Publication Date: 2023.02.21 HAMILTON SUNDSTRAND CORP

AI summary

A heat exchanger includes a pair of opposed, spaced apart heat exchanger plates defining a heat exchanger volume therebetween having an inlet and opposed outlet. A plurality of heat exchanger ribs are included within the heat exchanger volume. Each rib defines a rib body spanning the heat exchanger volume. Each rib body includes a plurality of slits therethrough to define a flow path through the heat exchanger ribs from the inlet to the outlet of the heat exchanger volume. The ribs and slits can be formed using ultrasonic additive manufacturing (UAM), for example.