Structural Heat Exchanger Assembly for Additive Vehicle Components
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Solution Overview
Problem
The practical implementation of additive manufacturing (AM) in transport structures is hindered by the need for labor-intensive and expensive joining techniques, such as welding, due to size limitations of 3-D printed components and the inability to produce large components in a single AM step, leading to inefficiencies in manufacturing complex geometries.
Innovation Solution
The integration of heat exchangers within vehicle components using a structure with headers and load-bearing struts or microtubes that enable fluid flow for heat transfer, allowing for the connection of subcomponents and nodes with adhesives, enabling efficient assembly and reducing reliance on traditional machining techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional welding and joining techniques are used to assemble large components, then structural integrity can be maintained, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The patent divides large components into multiple subcomponents that can be manufactured separately using additive manufacturing within size constraints, then assembled into a complete component. This segmentation allows AM technology to be applied while managing manufacturing complexity through standardized joining interfaces.
Solution Approach 2:
The patent integrates multiple functions into unified structures, such as combining structural support elements with fluid conduit pathways within the same additively manufactured component. This merging reduces the number of separate parts requiring assembly and eliminates traditional joining operations.
2Adaptability or versatility
If components are manufactured using additive manufacturing, then design freedom and structural efficiency improve, but component size is limited by build plate constraints
Solution Approach 1:
The patent divides large components into multiple subcomponents that can be manufactured separately using additive manufacturing within size constraints, then assembled into a complete component. This segmentation allows AM technology to be applied while managing manufacturing complexity through standardized joining interfaces.
Solution Approach 2:
The patent employs nested design where smaller functional elements, such as fluid conduits and cooling channels, are integrated within the hollow interiors of larger structural components. This nesting allows complex multi-functional components to be created without increasing external dimensions beyond AM build plate limits.
3Weight of moving object
If heat exchangers are integrated into vehicle components, then weight reduction and fuel efficiency improve, but manufacturing precision requirements increase
Solution Approach 1:
The patent integrates heat exchanger functionality directly into structural components such as suspension control arms and wheel hubs. By merging thermal management and structural support functions into single additively manufactured parts, the patent eliminates separate heat exchanger assemblies and their associated mounting structures, reducing total weight while leveraging AM's inherent precision for integrated fluid pathways.
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 efficient assembly of complex mechanical structures by allowing for the integration of heat exchangers within vehicle components, reducing weight and improving fuel efficiency while maintaining structural integrity, thereby overcoming the limitations of traditional manufacturing methods.
Implementation Method 1
one or more load-bearing struts extending to connect the first and second headers within the volume and configured to pass a second fluid through the volume for transferring heat to the first fluid
Implementation Method 2
a plurality of tubes extending through the shell structure to connect the first and second headers, the first and second headers each having second ports to enable a second fluid to flow through the tubes between the first and second headers to cool the first fluid
Data Source
AI summary
Techniques for structurally integrated heat exchangers are presented herein. A heat exchanger in accordance with an aspect of the present disclosure comprises a structure configured to enclose a volume for storing a first fluid, and to connect to a load. The heat exchanger further comprises a first and a second header first arranged in opposing inner walls of the structure. The heat exchanger further comprises one or more load-bearing struts extending to connect the first and second headers within the volume and configured to pass a second fluid through the volume for transferring heat to the first fluid, the second fluid configured to cool a different component in the vehicle.