Additively Manufactured Permeable Barrier Layer for Heat Exchangers

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Solution Overview

Problem

Conventional heat exchanger designs with double wall configurations face limitations in geometry, shape, and internal feature arrangement, which constrain thermal energy transfer and fluid flow performance, and are not ideal for applications requiring maximum heat transfer between interior and exterior surfaces, while also being inadequate for handling high pressures and temperatures.

Innovation Solution

An additively manufactured heat exchanger with a permeable barrier layer having a porous structure with non-uniform connected porosity, formed by layer-by-layer additive manufacturing, which is integrally connected between the exterior and interior walls, providing fluid permeability and structural support while optimizing thermal energy transfer and structural integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a double wall configuration with a gap is used to isolate leaks, then leak isolation capability is improved, but thermal energy transfer deteriorates due to the insulating effect of the empty volume

Engineering Contradiction:

Improveleak isolation capabilityVSAvoidthermal energy transfer

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent applies porous materials by filling the gap between inner and outer pressure vessels with a porous material that has controlled porosity (1-50%). This porous material allows thermal energy transfer through its interconnected pore structure while maintaining leak isolation capability, thus resolving the contradiction between reliability and thermal energy transfer efficiency.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent uses composite materials by creating a layered structure with non-permeable regions and permeable regions within the barrier layer. This composite structure combines the leak isolation properties of dense non-permeable regions with the thermal transfer properties of porous permeable regions, simultaneously achieving both improved reliability and thermal energy transfer.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If traditional manufacturing methods are used, then manufacturing simplicity is maintained, but geometry and internal feature arrangement are constrained

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidgeometry and internal feature arrangement

Core Design Contradiction:

Ease of manufactureVSShape

Solution Approach 1:

The patent applies parameter changes by utilizing additive manufacturing parameters (such as layer thickness, infill density, and pore size distribution) to create complex geometries and internal features that would be impossible with traditional manufacturing. This allows optimization of thermal energy transfer paths and fluid flow channels while maintaining manufacturing feasibility through digital modeling and layer-by-layer construction.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If the gap volume between walls is increased to provide drainage pathway, then leak drainage capability is improved, but thermal insulation increases which reduces heat transfer efficiency

Engineering Contradiction:

Improveleak drainage capabilityVSAvoidheat transfer efficiency

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent uses porous materials with controlled porosity (1-50%) in the barrier layer to provide both drainage capability and thermal transfer. The interconnected pores allow fluid drainage while the solid matrix maintains thermal conductivity, eliminating the need for large empty gap volumes and resolving the contradiction between drainage capability and heat transfer efficiency.

Inventive Principle:

Principle #31Porous materials

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 permeable barrier layer enhances thermal energy transfer, reduces weight, and improves structural integrity by allowing fluid flow in case of leaks, while minimizing potential leak paths and thermal stresses, thus addressing the limitations of traditional designs.

Implementation Method 1

a porous structure with non-uniform connected porosity

Methodology Applied

Scientific EffectPorosity: Porosity

Implementation Method 2

fusing powdered material by melting and solidifying the powdered material in a plurality of first regions to provide dense non-permeable first regions

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 3

fusing powdered material by sintering the powdered material in a second region surrounding and connected to the plurality of first regions to provide a porous second region having an open volume of surface connected porosity

Methodology Applied

Scientific EffectSintering: Sintering

Data Source

PatentUS11988469B2Additively manufactured permeable barrier layer and method of manufacture

Publication Date: 2024.05.21 HAMILTON SUNDSTRAND CORP

AI summary

A vessel includes first and second portions that are non-permeable to a fluid and a third portion that is permeable to fluid. The first potion defines at least one exterior wall defining an exterior container. The second portion defines at least one interior wall defining an interior container encapsulated by the exterior container. The third portion is positioned between the at least one exterior wall and the at least one interior wall, is integrally formed with the first portion and the second portion, and has a porous structure with non-uniform connected porosity.