Patent ID: 12209823

DETAILED DESCRIPTION

Reference will now be made to the drawings wherein like reference numerals identify similar structural features or aspects of the subject disclosure. For purposes of explanation and illustration, and not limitation, an illustrative view of an embodiment of a transition structure in accordance with the disclosure is shown inFIG.1and is designated generally by reference character100. Other embodiments and/or aspects of this disclosure are shown inFIGS.2-5. Certain embodiments described herein can be used to provide efficient and strong heat exchanger headers for high pressure applications.

Referring toFIGS.1and2, a transition structure100for a heat exchanger (not shown) can include a body101defining a dome cavity103. The dome cavity103can be hemispherical (e.g., as shown inFIGS.1,2,4, and5), partially spherical, or any other suitable ellipsoidal shape. Referring additionally toFIG.3, the dome cavity103can be configured to transition flow between at least one first channel105and a plurality of second channels107having a different number than the at least one first channel105.

The at least one first channel105can be a single first channel105in fluid communication with the dome cavity103. The single first channel105can have an inner diameter that is the same as the diameter of the dome cavity103. Any other suitable relative diameter and/or shape between the first channel105and the dome cavity103is contemplated herein.

The plurality of second channels107can be two or more second channels107. Each channel107can have a second channel opening109in fluid communication with the dome cavity103.

In certain embodiments, the plurality of second channels107can include nine second channels107. Any suitable number of second channels107is contemplated herein. As shown inFIG.3, the transition structures200can include four second channels, for example. Transition structure200can be otherwise similar to structure100, for example.

Each second channel107can extend from the body101and become parallel with the other second channels107(e.g., as shown inFIG.2). The second channels107can extend from the dome cavity at one or more angles and bend back to be parallel, for example. In certain embodiments, the second channels107can be limited to be no more than about 40 to 45 degrees to be self-supporting in build during additive manufacturing. For example, the build direction can be parallel with the centerline axes of the second channels, e.g., as shown. Any suitable number is contemplated. Any other suitable method of manufacturing is contemplated herein (e.g., lost wax casting or any other suitable method).

The nine second channels107can be arranged in a three by three square (e.g., as shown inFIG.2). In certain embodiments, each second opening109can define a center axis (e.g., orthogonal to the plane defining the opening109) that is coincident with a center point (e.g., such that all normal lines of each opening109extend through a center point of the theoretical full sphere from which the hemisphere comes) of the dome cavity103. Any other suitable relationship between one or more center axes of the second openings109and the center point of the dome cavity103is contemplated herein.

In accordance with at least one aspect of this disclosure, as shown inFIGS.3and4, a heat exchanger header300,400can include one or more transition structures. The one or more transition structures can be and/or include any suitable transition structure disclosed herein, e.g., structure100as described above. In certain embodiments, the one or more transition structures100can include a plurality of transition structures100. In certain embodiments, the plurality of transition structures100can include a plurality of successive transition structures100of reducing size toward a core direction. For example, a dome cavity103of a smaller transition structure can be in fluid communication with one of a respective second channel of a larger transition structure. Embodiments of a header can include any suitable number of sub-divisions to transition from an inlet/outlet into the suitable number of core channels.

In accordance with at least one aspect of this disclosure, a method for additively manufacturing a heat exchanger can include building a transition structure comprising a body101defining a dome cavity103that is configured to transition flow between at least one first channel105and a plurality of second channels107having a different number than the at least one first channel105. The transition structure can be and/or include any suitable transition structure disclosed herein, e.g., structure100as described above. Building the transition structure100can include building the dome cavity103such that a vertical build direction is parallel with a center axis of the dome cavity103and/or aligned with each second channel107to build the transition structure100without support structure. The method can include any other suitable method(s) and/or portion(s) thereof. Any other suitable method to make one or more embodiments of this disclosure is contemplated herein.

Embodiments can use a spherical shape in transition portions to handle high stresses with thinner walls. Stress in high pressure can be well distributed in the embodiment of a structure100. The spacing of openings109apart from each other can be spaced out evenly so stresses are substantially the same throughout the cavity103.

By providing a stronger structure, the weight of the overall heat exchanger can be reduced. In certain embodiments, each step down from larger flow channels to multiple smaller flow channels, the walls can be thinner. Embodiments also promote even flow to all the second channels or vice versa. The direction of flow can be either way and embodiments can provide a strong transition. In certain embodiments, the dome cavity can be positioned in the direction of flow. Embodiments can be built using additive manufacturing without support structure.

Embodiments can include an integrated heat exchanger header for ultra-high pressure operation with a modular design that provides a low-stress option for transitioning the flow from one channel into many (or vice versa). Embodiments can utilize spherical and cylindrical shapes to minimize pressure stresses due to the high pressure at flow transitions. For example, flow from one branch can enter a hemisphere from which several smaller channels emanate. Embodiments can include one flow path splits into nine channels for example. Alternatively, the flow can enter the nine smaller channels and converge to one flow path. Any other suitable number of channels are contemplated herein.

The diameter of the sphere can be modified to accommodate any number of splits. For example, the flow path can be split into four channels at two locations in the heat exchanger header, e.g., as shown inFIG.3. Embodiments of a spherical transition can be easily scaled to create modular, fractal-like flow paths that continue to split one flow path into many in a way that ensures stress from ultra-high pressure operation remains low.

Embodiments can offer an integrated header design that seamlessly transitions between heat exchanger core and external system plumbing, survives an ultra-high pressure environment, and can be additively manufactured without internal supports. Embodiments can enable a modular, spherical transition path for ultra-high pressure fluid to split or converge while traveling through an additively manufactured heat exchanger. The flow can easily split into many smaller paths by way of hemispherical features. Alternatively, the flow can converge from multiple paths into one through the same feature, for example. Where previous designs for headers have relied on the merging and splitting of channels, often in discrete, stacked layers, to connect external plumbing to heat exchanger cores, embodiments can route circular paths through hemispherical transition paths such that stresses from ultra-high pressure loads remain low. As such, the resulting header performs well in ultra-high pressure applications. Furthermore, embodiments can be additively manufactured without the need for internal supports. Embodiments can inherently allows for patterning of the feature, which eases the CAD burden inherent in connecting hundreds to thousands of channels to one inlet or outlet. The cylindrical and spherical geometry can also be less computational intensive for the CAD program than current lofted designs, reducing file size and improving CAD rebuild times.

Those having ordinary skill in the art understand that any numerical values disclosed herein can be exact values or can be values within a range. Further, any terms of approximation (e.g., “about”, “approximately”, “around”) used in this disclosure can mean the stated value within a range. For example, in certain embodiments, the range can be within (plus or minus) 20%, or within 10%, or within 5%, or within 2%, or within any other suitable percentage or number as appreciated by those having ordinary skill in the art (e.g., for known tolerance limits or error ranges).

The articles “a”, “an”, and “the” as used herein and in the appended claims are used herein to refer to one or to more than one (i.e., to at least one) of the grammatical object of the article unless the context clearly indicates otherwise. By way of example, “an element” means one element or more than one element.

The phrase “and/or,” as used herein in the specification and in the claims, should be understood to mean “either or both” of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Multiple elements listed with “and/or” should be construed in the same fashion, i.e., “one or more” of the elements so conjoined. Other elements may optionally be present other than the elements specifically identified by the “and/or” clause, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, a reference to “A and/or B”, when used in conjunction with open-ended language such as “comprising” can refer, in one embodiment, to A only (optionally including elements other than B); in another embodiment, to B only (optionally including elements other than A); in yet another embodiment, to both A and B (optionally including other elements); etc.

As used herein in the specification and in the claims, “or” should be understood to have the same meaning as “and/or” as defined above. For example, when separating items in a list, “or” or “and/or” shall be interpreted as being inclusive, i.e., the inclusion of at least one, but also including more than one, of a number or list of elements, and, optionally, additional unlisted items. Only terms clearly indicated to the contrary, such as “only one of” or “exactly one of,” or, when used in the claims, “consisting of,” will refer to the inclusion of exactly one element of a number or list of elements. In general, the term “or” as used herein shall only be interpreted as indicating exclusive alternatives (i.e., “one or the other but not both”) when preceded by terms of exclusivity, such as “either,” “one of,” “only one of,” or “exactly one of.”

Any suitable combination(s) of any disclosed embodiments and/or any suitable portion(s) thereof are contemplated herein as appreciated by those having ordinary skill in the art in view of this disclosure.

The embodiments of the present disclosure, as described above and shown in the drawings, provide for improvement in the art to which they pertain. While the subject disclosure includes reference to certain embodiments, those skilled in the art will readily appreciate that changes and/or modifications may be made thereto without departing from the spirit and scope of the subject disclosure.