Monolithic Heat Exchanger Layout With Wrapped Nested Channels
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing heat exchangers have limited design complexity, which hinders their thermal efficiency.
Innovation Solution
The formation of heat exchangers with monolithically integrated channels, where one channel is partially wrapped around or within another, using materials like Cu, Ni alloy, or Al, and laser sintering technology to create complex fluid pathways.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional machining methods are used to form heat exchanger channels, then manufacturing simplicity is maintained, but design complexity and thermal efficiency are limited
Solution Approach 1:
The patent replaces conventional mechanical machining methods with laser sintering technology to form heat exchanger channels. This substitution enables the creation of complex three-dimensional channel configurations including wrapped and intersecting channels that cannot be achieved through traditional machining, while maintaining manufacturing feasibility through additive manufacturing processes
Solution Approach 2:
The patent changes the manufacturing process parameters from conventional machining to laser sintering of metal powder. This parameter change allows for monolithic formation of complex channel structures with varying cross-sections, wrapped configurations, and integrated designs that would be extremely difficult or impossible to achieve with traditional mechanical methods
2Reliability
If simple channel designs are used in heat exchangers, then manufacturing ease is maintained, but thermal efficiency is not maximized
Solution Approach 1:
The patent implements nested channel configurations where channels are wrapped around or within other channels, creating multi-layered fluid pathways. This nesting arrangement increases the heat transfer surface area and improves thermal efficiency by allowing closer proximity between hot and cold fluid streams while maintaining a compact overall structure
Solution Approach 2:
The patent transitions from traditional two-dimensional channel layouts to three-dimensional wrapped and intersecting channel configurations. This dimensional change enables fluid streams to follow complex spatial paths that maximize heat transfer surface area and optimize thermal efficiency within a compact volume
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
Enhances thermal efficiency by allowing unique fluid flow configurations that cannot be achieved with conventional machining, improving cooling and heating applications.
Implementation Method 1
laser sintering technology to create complex fluid pathways
Data Source
Figure 1~2B
Figure 3~4B
AI summary
A method of forming a heat exchanger, comprising monolithically forming a body (102) to define at least two channels (101, 103) configured to allow fluid to flow therethrough, at least one (101) of the at least two channels (101, 103) at least partially wrapping around or within at least one other of the at least two channels (103).