Multi-Material Heat Exchanger Core With Additive Support Structure
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Solution Overview
Problem
Conventional heat exchangers are limited by the use of a single material, which restricts their performance in terms of thermal conductivity, structural integrity, and weight optimization, despite advancements in additive manufacturing offering potential for varied geometries and materials.
Innovation Solution
The method involves additively manufacturing a heat exchanger core using a first material and process, such as LPBF, and a support structure using a second material and process, like DED, allowing for material gradients and diverse structural configurations, including solid shells or cages, to enhance thermal conductivity and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single material is used for the entire heat exchanger, then manufacturing simplicity is maintained, but thermal conductivity and structural integrity are compromised
Solution Approach 1:
The patent applies composite materials by combining two different materials with distinct properties: a first material (e.g., aluminum alloy) for the heat exchanger core to maximize thermal conductivity, and a second material (e.g., titanium alloy or steel) for the support structure to provide superior structural integrity and strength. This composite approach allows each component to be optimized for its specific function, resolving the contradiction between manufacturing simplicity and structural performance.
2Ease of manufacture
If a single material is used for the entire heat exchanger, then material selection is simplified, but thermal conductivity performance is limited
Solution Approach 1:
The patent applies local quality by assigning different material properties to different regions of the heat exchanger based on functional requirements. The core region, where heat transfer is critical, uses a material with high thermal conductivity (e.g., aluminum alloy), while the support structure region, where mechanical strength is critical, uses a different material. This localized material optimization resolves the contradiction between material selection simplicity and thermal conductivity performance.
3Device complexity
If additive manufacturing is used with a single material, then process complexity is reduced, but geometric flexibility and material optimization are limited
Solution Approach 1:
The patent applies segmentation by dividing the heat exchanger into two distinct components manufactured through separate additive manufacturing processes: the heat exchanger core and the support structure. Each component is manufactured independently using material and process parameters optimized for its specific requirements, then assembled together. This segmentation resolves the contradiction between process complexity and geometric flexibility, allowing each segment to be optimized without compromising the other.
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 approach enables the optimization of heat exchanger performance by combining materials with high thermal conductivity for the core and structural integrity for the support structure, addressing limitations of single-material heat exchangers and improving overall efficiency and durability.
Implementation Method 1
The first additive manufacturing process can be or include a laser powder bed fusion (LPBF) process
Implementation Method 2
The second additive manufacturing process can be or include a directed energy deposition (DED) process
Implementation Method 3
The first material can be selected for heat transfer and/or can include a higher thermal conductivity than the second material
Implementation Method 4
The heat exchanger core has one or more fluid channels
Data Source
Figure 1~2
Figure 3A
Figure 3B~4
AI summary
A method can include additively manufacturing a heat exchanger core (201, 301) having one or more fluid channels (203, 303) using a first additive manufacturing process and a first material. The method can also include additively manufacturing a support structure (405) around the heat exchanger core using a second additive manufacturing process different from the first additive manufacturing process and a second material different from the first material after additively manufacturing the heat exchanger core.