EA038501B1 - Thermal management system - Google Patents

Abstract

A thermal management system (800) includes a housing (802) and a monolithic core structure (804) disposed within the housing. An outer surface (806) of the core structure defines at least part of a first passageway (808). An inner surface (810) of the core structure defines at least part of a second passageway (812). The core structure includes a separator wall (820) that isolates a first flow passing through the first passageway from a second flow passing through the second passageway. The first passageway is in thermal communication with the second passageway. The core structure includes one or more heat exchanger features (830), or fins, that are positioned within the first passageway, the second passageway or both said passageways. The core structure may have a compliant segment (840) coupled to two or more walls.

Description

Technology area

Embodiments may relate to a thermostatic device and a related method.

Background of the invention

Thermoregulatory devices can be made in the form of heat exchangers. Heat exchangers can be used with motors to provide heat transfer between one or more fluids. For example, a first fluid at a relatively high temperature can flow through the first channel, while a second fluid at a relatively low temperature can flow through the second channel. The first and second channels can be in thermal contact or in close proximity to each other, which allows heat transfer from the first fluid to the second fluid. Thus, the temperature of the first fluid can be lowered and the temperature of the second fluid can be increased.

Conventional heat exchangers can contain a large number of fluid channels, each formed using a specific combination of plates, strips, films, fins, tubes, etc. Each of these parts can be individually positioned, oriented and connected to the support structure, for example, by soldering, welding or other joining method. Thus, for example, one particular heat exchanger for one engine contains 250 parts to be assembled into a single sealed component. The manufacturing time and costs associated with assembling such a heat exchanger are high, and the likelihood of fluid leaks between channels or from the heat exchanger is increased due to the number of connections formed. In addition, special manufacturing requirements can impose restrictions on the number, size and configuration of heat exchange elements that can be contained in the heat exchanger, for example, within the fluid channels.

Accordingly, it may be desirable to provide an engine with a heat exchanger other than currently available heat exchangers.

The essence of the invention

In one embodiment of the invention, the temperature control device comprises a housing. The device also contains a monolithic central structure located within the housing. The outer surface of the central structure defines at least a portion of the first channel. The inner surface of the central structure defines at least part of the second channel. The central structure contains a dividing wall that isolates the first flow through the first channel from the second flow through the second channel. The first channel is in thermal contact with the second channel. The central structure contains one or more heat exchange elements, or fins, which are located in the first channel, the second channel, or in both of these channels. Heat transfer elements are characterized by their thickness and density of distribution. In this case, the central structure additionally contains a deformable component, the first end of which is attached to the housing structure, and the second end is attached to the dividing wall. In another embodiment, the deformable component attaches one dividing wall to another dividing wall.

In one embodiment, the thermostatic control device comprises a housing. The device also contains a monolithic central structure located within the housing. The outer surface of the central structure defines at least part of the first channel, and the inner surface of the central structure defines at least part of the second channel. The central structure contains a dividing wall that isolates the first flow through the first channel from the second flow through the second channel. The first channel is in thermal contact with the second channel. The central structure contains one or more heat exchange elements, which are located in the first channel, the second channel, or in both of these channels. Heat transfer elements are characterized by their thickness and density of distribution. In addition, the center structure contains two or more different materials that are non-uniform and not alloyed with each other.

In one embodiment, the thermostatic control device comprises a housing. The device also contains a monolithic central structure located within the housing. The outer surface of the central structure defines at least part of the first channel, and the inner surface of the central structure defines at least part of the second channel. The central structure contains a dividing wall that isolates the first flow through the first channel from the second flow through the second channel. The first channel is in thermal contact with the second channel. The monolithic central structure contains one or more ribs, which are located in the first channel, the second channel, or in both of these channels. The ribs are complex. The monolithic central structure has a surface layer or coating made of

- 1 038501 material other than the material of the main body of the central structure, the material of said one or more ribs, or material of both the central structure and the ribs.

Brief Description of Drawings

Below is a complete description of the invention, including the most preferred variants of its implementation, intended for a person skilled in the art and made with reference to the accompanying drawings.

FIG. 1 is a perspective view of a heat exchanger according to an embodiment of the invention.

FIG. 2 is a cross-sectional perspective view of the heat exchanger shown in FIG. 1.

FIG. 3 is another perspective cross-sectional view of the heat exchanger shown in FIG. 1.

FIG. 4 is an enlarged perspective view of the first fluid passage in the heat exchanger of FIG. 1.

FIG. 5 is a sectional view of the heat exchanger shown in FIG. 1.

FIG. 6 is an enlarged sectional view of a second fluid passage in the heat exchanger of FIG. 1.

FIG. 7 illustrates a method for forming a heat exchanger according to an embodiment of the invention.

FIG. 8 is a schematic view of a heat exchanger according to an embodiment of the invention.

The repeated use of reference numbers in the description and drawings is intended to re-designate the same or similar elements or parts of the invention.

Detailed description of the invention

A heat exchanger and a method for additive manufacturing of a heat exchanger are proposed. The heat exchanger has fluid passages formed by additive manufacturing methods that allow for smaller fluid passages with thinner walls and complex and shaped heat exchange elements. For example, these channels can be curved, heat exchange elements (ribs, antennae, etc.) can be inclined relative to their base, can have a thickness of less than 0.01 cm and can be located with a density of less than 12 elements / cm. In addition, the heat transfer fins can be inclined with respect to the walls of the fluid channels, while the adjacent fins can be located in a spiral, offset or staggered relative to each other.

FIG. 1, a central heat exchanger structure 100 of a thermostatic control device is shown to describe one embodiment of the invention. A heat exchanger can transfer heat between two or more fluids during operation.

For example, a heat exchanger can transfer heat from the lubricating oil to the air in the engine. In another embodiment, the heat exchanger may receive suitable types of fluids for use in a heat transfer process. In addition, the ideas and heat transfer structures described herein can be used in the automotive, aviation, shipping, and other mobile or stationary industries to assist in transferring heat between fluids.

FIG. 1 shows a thermostatic control device containing a heat exchanger for clarification of its operation. The heat exchanger may include an outer casing 101 extending between the left side 102 and the right side 104 in a first direction, for example in the X direction. In addition, the casing 101 extends between the front side 106 and the back side 108 in a second direction, for example in the Y direction. also extends between the top side 110 and the bottom side 112 in a third direction, for example the Z direction. The X, Y and Z directions are mutually perpendicular and thus define an orthogonal coordinate system. The heat exchanger and the X, Y, Z coordinate system are used herein solely to explain aspects of the subject invention and do not limit the scope of the invention. In this regard, directional words such as left and right, front and back, and top and bottom are only used to indicate the relative position of the two sides of the heat exchanger in the X, Y and Z directions, respectively.

An oil inlet 120 and an oil outlet 122 are formed on the upper side of the heat exchanger. Thus, oil (as shown by arrows 124) enters the heat exchanger only through the indicated inlet, passes through the first fluid passages 126 (FIG. 2) and exits the heat exchanger through the indicated outlet, as described in detail below. In addition, an air inlet 130 is located on the front side of the heat exchanger, and an air outlet (not shown) is located on the rear side of the heat exchanger. Thus, air (as shown by arrows 134) enters the heat exchanger through the indicated air inlet and passes through the second fluid passages 136. The first and second channels are in thermal contact with each other to transfer heat between fluids passing through them. The first and second channels are separated from each other in the sense that the respective fluids do not physically mix with each other. In this regard, each of the first channels and each of the second channels can be separated by the walls of the heat exchanger. In the depicted version

- 2 038501 embodiments, the thickness of the walls of the outer casing varies along their length and is in the range from about 0.076 to 0.025 cm.

Referring to FIG. 2 and 3, the heat exchanger defines an inlet chamber 140 and an outlet chamber 142, which are in direct flow communication with the oil inlet and oil outlet, respectively. The inlet chamber allows oil to be drawn away from the inlet and distributed to all of the first fluid passages. In contrast, the outlet chamber allows oil from all of the first fluid passages to be drawn into the outlet before the oil exits the heat exchanger.

The inlet chamber and the outlet chamber are separated along the Y direction by an intermediate wall 144 so that the inlet chamber and the outlet chamber are in fluid communication only through the first fluid passages. As shown in particular in FIG. 4, the intermediate wall extends from the top side in the Z direction to the bottom side (not reaching the bottom side) to separate the first fluid passages and form an inflow zone 146 and a drain zone 148. Thus, when oil enters the heat exchanger through the inlet for oil and the inlet chamber, the first fluid channels generally guide the oil downward along the Z direction into the inlet zone. The oil then flows around the intermediate wall and rises up along the Z direction in the drain area towards the outlet chamber. According to an embodiment, the intermediate wall extends from the upper side along the Z direction to the lower half or lower quarter of the heat exchanger (i.e., along about 50-75% of the height of the heat exchanger in the Z direction). In another embodiment, the intermediate wall can extend a different distance from the top side. Alternatively, each fluid channel can be isolated (eg, so that oil does not mix between adjacent channels) and be U-shaped.

The single intermediate wall is depicted in such a way that the first channels form a U-shape, whereby it guides the oil through the heat exchanger twice. More specifically, the oil flows substantially along the entire length of the heat exchanger downward in the Z direction to the inflow area and upward in the Z direction to the drain area. In addition, it is shown that air makes one pass through the heat exchanger, i.e. from the front to the rear, substantially in the Y direction. However, it should be understood that the heat exchanger, and in particular the first and second channels, can direct their respective fluid in any suitable number of passes to achieve the desired fluid flow rate and heat transfer characteristics. For example, the heat exchanger may have multiple intermediate walls, baffles and / or cavities that guide oil through the heat exchanger four or more times. Likewise, intermediate walls, baffles, and / or cavities in the second fluid path can direct air to pass through the heat exchanger multiple times to increase dwell time, collision opportunities, and ultimately the amount of heat transferred.

For clarity, not all heat transfer elements are shown in the drawings. However, with reference to FIG. 4-6 describe the various fluid passages and associated heat exchange elements. FIG. 4 is a cross-sectional side view of a heat exchanger showing the first fluid passages. FIG. 5 is an enlarged perspective view of the section shown in FIG. 3. In FIG. 6 is an enlarged view of the second fluid passages.

The first fluid channels may contain a first set of heat exchange elements. Heat transfer elements are depicted in this embodiment in the form of strips or ribs 160. These strips or ribs can increase the surface area to improve the transfer of thermal energy. The ribs in other embodiments are linear or curved and are angled with respect to a plane defined by the wall of the fluid channel. As shown in FIG. 5, the ribs may be located at a first angle 162 with respect to the walls of the first fluid passages. For example, in some embodiments, said first angle may be from about 10 ° to 80 °, from about 30 ° to 60 °, or about 45 °. The specified angle may vary along the length of the elongated heat transfer element to impart twist or spirality. Thus, the heat transfer surface of each fin can be relatively increased. Unless otherwise indicated, the bar extends across the channel and is attached at both ends, while the rib is attached at one end and not secured at the other end. References to heat transfer elements, fins, strips, projections, tendrils, etc. are interchangeable unless context or terminology indicates otherwise.

As shown in FIG. 4, in accordance with the illustrated embodiment, the ribs are staggered. Staggering the ribs can increase fluid contact with the ribs. As used herein, a fluid channel with offset or staggered heat exchange elements is a channel in which elements located adjacent to each other along the first or second direction of fluid flow are offset relative to each other in a direction perpendicular to said first or second direction. It should be noted that the amount of displacement and spacing of the ribs along the first direction of fluid flow can be varied without departing from the scope of the invention. Additionally or alternatively, the ribs can be similarly staggered in the second fluid channel. The first channel defines a first direction of fluid flow, and the second channel defines a second direction of fluid flow.

FIG. 6 is an enlarged view of the second fluid passages. Similar to the first fluid passages, the second passages may have heat transfer surfaces, such as fins, to improve heat transfer. The other ribs can be located at any suitable angle relative to the channel wall. For example, as shown in the drawing, the ribs 170 are located at a second angle 172 with respect to the walls of the second fluid channels. For example, in some embodiments, said second angle may be from about 10 ° to 80 °, from about 30 ° to 60 °, or about 45 °. Thus, the heat transfer surface of each fin can be increased.

One or more of the second fluid channels may be fan-shaped or may have an increasing width towards the underside of the heat exchanger to provide a curved overall profile of the heat exchanger. The curved profile can help, for example, to follow the contour of the engine on which the heat exchanger can be mounted. The second fluid channels may be partially delimited by the first wall 180 and the second wall 182. A third angle 184 may be formed between said first and second walls. The third angle may be relatively small, for example, less than 5 °, or large, for example, more than 40 °. depending on the location in the center section and on other parameters depending on the specific application.

The additive manufacturing methods described herein allow one-piece fabrication of very thin ribs within a monolithic core. For example, each rib can have a thickness in the range of about 0.01 to about 0.2 cm. In other embodiments, the ribs can have a thickness in the range of about 0.2 to about 0.5 cm. The ribs can be made to a suitable thickness. up to one additive layer, for example 10 μm. The ability to manufacture extremely thin fins, strips or other protrusions can enable the manufacture of heat exchangers with very high density of heat exchange elements. For example, the ribs can be made with a density of about 2-13 ribs / cm. The ribs can be made with a density of about 10 ribs / cm or more. However, according to other embodiments, the density of the arrangement of the fins can be more than 12 heat exchange elements / cm. In addition, all of the ribs may be the same and evenly spaced across each fluid path, or all of the ribs may be different and unevenly spaced.

The first and second fluid channels have non-circular geometric shapes. Geometries can be chosen to increase the surface area available for heat transfer. For example, the cross-sectional profiles of the first and second channels can be square or rectangular. In this regard, each channel may have a height that is, for example, an average distance measured perpendicular to the flow of fluid in said channel. For example, the height of the channel can be the average distance between the walls of the corresponding fluid channel, for example from one wall of the channel to the other wall along a direction perpendicular to the walls.

In accordance with the embodiment shown in FIG. 5, each of the first channels has a height of 190 and each second channel has a second height of 192. The indicated height of the first channel and the height of the second channel may be the distance between the first wall 180 and the second wall 182 for a given channel. The height of the first channel and the height of the second channel may be the same along the length of the corresponding channel, or may vary along it, as shown in FIG. 6. In addition, all channels in a channel set can have the same or different heights.

The height of the first channel and the height of the second channel can be selected to improve fluid flow through the corresponding channel. For example, the height of the channel through which the oil flows may be less than the height of the channel through which the air passes. In accordance with one embodiment, the height of the first channel and / or the height of the second channel is from about 0.025 to 2.54 cm. The first channels and second fluid channels can be sized and geometries based on parameters depending on the particular application.

Each of the first and second channels may be straight, curved, serpentine, spiral, sinusoidal, or any other suitable shape. For example, as shown in FIG. 4, the first channel is curved, i. E. arcuate or U-shaped. The heat exchanger can have performance-enhancing geometries and heat exchange elements that are facilitated in practice by an additive manufacturing process, as described below. In some embodiments, the first channel and the second fluid channel may have heat exchange surfaces or features, such as fins, to aid in the heat transfer process.

The heat exchanger parts can be made using a suitable material, with the appropriate geometry, density and thickness required to provide the required structural support for the heat exchanger during a particular mode of operation. For example, the outer walls 196 of the heat exchanger can be made of rigid thermal insulation material. In addition, the corresponding outer walls can be thicker and denser to provide structural support for the loads experienced by the heat exchanger during installation, assembly and operation of the gas turbine engine. In contrast, the inner walls (eg, walls 180 and 182 of the second fluid passages) can be thinner or made of more thermally conductive materials to improve heat transfer. For example, in accordance with one embodiment, the walls of the heat transfer channels can be made of a heat-conducting metal alloy and can have a thickness of less than 0.07 cm. In accordance with another embodiment, the walls of the heat transfer channels can have a thickness of about 0.03 cm and can be selected at least in part on the basis of the operating pressure and temperature, and also on the basis of which fluid will pass through the channel.

In accordance with the illustrated embodiment, the first channels and the second fluid channels are of a cross-flow design, i. E. oil and air flows are perpendicular to each other. In another embodiment, the first channels and second fluid channels operate as a counter-current arrangement, with the heat exchanger configured such that the first channels and second channels are substantially parallel and the respective fluid flows move in opposite directions in the respective channels. In addition, in accordance with some embodiments, fluids can move in their respective channels in the same direction.

Available methods of additive manufacturing can provide the ability to make heat exchangers with a specific size or shape. The support contours or outer profiles of the heat exchangers can be square, circular, curved, or any other suitable shape, for example, to provide a snug fit in an otherwise unused engine space, or to provide greater streamlining or efficiency. In addition, the fluid passages in the heat exchanger can have a size or configuration depending on the particular application and can have specific profiles, thinner walls, lower channel heights, and more complex and shaped heat exchange elements.

A method 200 is provided for forming a monolithic heat exchanger in accordance with one embodiment of the invention. This method can be used to form a heat exchanger. Referring to FIG. 7, the method includes additively fabricating a first duct body within an outer heat exchanger body in step 210, the first duct body defining a first fluid path. Step 220 includes additive manufacturing of a first set of heat transfer elements within a first fluid passageway, each element of said first set of heat transfer elements having a first thickness. Step 230 includes additive manufacturing of a second conduit body within the outer body, the second conduit body defining a second fluid conduit. Step 240 includes additive manufacturing of a second set of heat transfer elements within a second fluid channel, each element of said second set of heat transfer elements having a different, second thickness. The first and / or second thicknesses can have a value of less than about 0.03 cm. However, as noted in this description, these thicknesses can differ from each other in size, shape, location relative to the base and composition of the material. In addition, differences may depend on in which channel or along the length of which one of the channels (or both channels) they are located.

In one embodiment, the heat exchange device may comprise a pre-cooling stage with a tubular shell and one or more thermally deformable elements and a plate-rib configuration. This configuration can provide increased efficiency and compactness. The deformable member can expand / contract, bend or bend under load to prevent breakage. Components with different coefficients of thermal expansion or different temperature profiles can lead to thermal stresses in and between different areas of the thermostatic control device. Deformable members can be used to relieve at least some thermal stress.

FIG. 8 depicts a temperature control device 800 including a housing 802 in accordance with an embodiment of the invention. The specified device contains a monolithic central structure 804 located inside the housing. The outer surface 806 of the central structure defines at least a portion of the first channel 808. The inner surface 810 of the central structure defines at least a portion of the second channel 812. The central structure includes a partition wall 820 isolating a first flow (not shown) passing through the first channel from the second flow (not shown) passing through the second channel. An enlarged cross-sectional view of the dividing wall depicts the dividing wall of the central portion 804A and the cover 822 located on the outer surface. In the illustrated embodiment, the coating is shown applied over only a portion of the outer surface. In the illustrated embodiment, the central

- 5 038501 the structure is steel and the coating is a non-contaminating anticorrosive nitride finish.

The first channel is in thermal contact with the second channel. The central structure contains one or more heat exchange elements 830 located in the first channel. Heat exchange elements in the second channel are not shown in order to avoid image clutter. The depicted heat transfer elements are linear bars extending perpendicularly across the first channel to increase the heat transfer surface area. The thickness of the heat exchange elements is approximately equal to the wall thickness of the central structure, and the density of their distribution is expressed as a ratio of 4 to 1, i.e. along a length segment equal to the channel width, there are four heat exchange elements. The drawing does not show the profile of the heat exchange element having an elongated drop-like shape, and the fact that the heat exchange elements are staggered relative to adjacent elements. The heat transfer elements can be configured to keep the fluid close to their surface to minimize laminar flow properties and increase collisions with the flowing fluid by enhancing the formation of a turbulent boundary layer. In one embodiment, the specified profile is made relative to the surface of the central part so as to create a Coanda effect along at least a portion of the length of one or more heat exchange elements.

As shown in FIG. 8, the central structure comprises a deformable component 840, a first end 842 of which is attached to the body structure and a second end 844 of which is attached to a dividing wall. In another embodiment, the deformable component attaches one dividing wall to another dividing wall. As shown in the drawing, the device may contain one or more deformable components. These deformable devices can be in a state in which they are bent or twisted, and in another state in which they are stretched or straightened. Thus, depending on the state, the deformable component may have one or more curvatures or bends. These bends can be, for example, S-shaped or corrugated. The depicted embodiment has simple curves and is made of a material that is different from that of the central structure and is more flexible. The heat transfer elements of the central structure can be selected based on one or more of the following parameters: thermal conductivity, erosion resistance, corrosion resistance, chemical resistance, or resistance to pollution. In other embodiments, the materials may be the same, but the thicknesses may differ.

The described thermostatic control devices can be manufactured or manufactured using suitable processes. However, in accordance with some aspects of the present invention, the heat exchanger can be made using an additive manufacturing process, such as a 3D printing process. Using such a process may allow the heat exchanger to be formed integrally as a single monolithic component as described above in accordance with one embodiment. The specified manufacturing process can provide the possibility of obtaining a heat exchanger made in one piece and containing various elements that cannot be obtained using other manufacturing methods.

As used herein, the expressions additive manufactured or additive manufacturing technologies or processes refer generally to manufacturing processes in which successive layers of material (s) are superimposed on each other to build up a three-dimensional component layer by layer. Successive layers essentially fuse together to form a monolithic component, which may have a set of integral subcomponents. In contrast, cast or molded parts that are welded together are not monolithic.

Suitable additive manufacturing technologies in accordance with the invention include, for example, directional modeling (FDM), selective laser sintering (SLS), 3D printing such as inkjet or laser, stereolithography (SLA), direct selective laser sintering (DSLS), electronic beam sintering (EBS), electron beam melting (EBM), laser forming melting (LENS), laser cladding fabrication (LNSM), direct metal deposition (DMD), digital optical processing (DLP), laser direct sintering of metals ( DMLS) and other processes selected based on the parameters and requirements, depending on the specific application.

The additive manufacturing processes described in this document can create components using a material suitable for the end use. Depending on the use of the component, the material can be plastic, metal, concrete, ceramic, cermet, polymer, epoxy resin, photopolymer resin, or other material. The starting material can be in solid, liquid, powder form, sheet material, wire or other form. In one embodiment, the heat exchanger can be made partly of a specific material, entirely of a specific material, or a combination of materials. In one embodiment, the combination may contain various metals and their alloys. Suitable metals include aluminum, beryllium, copper, iron, magnesium, nickel, rhenium, tin, and titanium. Suitable alloys may include alloys with the above metals, including nickel alloys, chromium alloys, titanium alloys, magnesium alloys, aluminum alloys, and austenitic alloys. Suitable austenitic alloys may include ultra-high-strength chromium-nickel alloys (for example, alloys under the name Inconel® available from the Special Metal Corporation) and cobalt-chromium alloys.

In addition, various materials and methods can be used to bond these materials and are considered to be within the scope of the invention. Used in this document, the term fusion can refer to the process of creating a tie layer based on the requirements depending on a particular application. For example, if the object is made of a polymer, fusion may refer to creating a thermosetting bond between the polymer materials. If the object is made of epoxy resin, then the bonding can be done using a cross-linking process. If the material is a ceramic or cermet, then the bond can be formed using a sintering process. If the material is a powdered metal, then the bond can be formed through a melting process. It is possible to use other methods of fusing materials to make a component using additive manufacturing.

In one embodiment, the additive manufacturing process described herein provides the ability to produce a single component from multiple materials. That is, the heat exchanger can be made from a suitable mixture of the above materials and / or from different materials in different parts or components. For example, a component may contain a collection of layers, components, or parts that are formed using different materials, processes, and / or different additive manufacturing machines and still form a monolithic part. Thus, it is possible to design components that contain different materials and have different material properties to suit the parameters of a specific application.

In this application, there may be a transition piece between parts of different materials. Alternatively, there may be a clear boundary layer between two (or more) materials. By using a transition piece, the performance of the component can be influenced. For example, materials with different coefficients of thermal expansion (CTE) may have a concentration gradient that goes from 100% concentration of one material to 100% concentration of another material, with the concentration in the middle of the transition region being approximately 50% for each material. Depending on the requirements of the application and on the properties of the material, different rates of change of the gradient and the uniformity of this gradient along the transition part can be used. In addition to thermal expansion, other factors can be taken into account, which may include a preliminary calculation of the total cost (using cheaper materials in cases where there is no need for more expensive materials), hardening (using stronger materials when increasing strength is required), etc. ...

It is possible to create bimetallic combinations. In such an application, differences in material characteristics can be useful. Referring to the CTE example, when the layers of two materials with different CTEs are located next to each other, they can expand or contract to different degrees depending on the temperature change. Accordingly, in one embodiment, the heat exchanger may include heat exchange elements, such as fins or tendrils, manufactured using bimetallic layer forming processes such that the physical configuration of the fin also changes as the temperature of the fin changes. This circumstance can be used to selectively direct the flow of the fluid passing along the ribs, depending on its temperature. This can be used to increase or decrease the flow rate through the heat exchanger (again depending on the temperature of the contacting fluid). In addition, the ribs in one channel may differ from the ribs in another channel (with a different fluid). For example, as the temperature of the exhaust gas stream increases, the fins can retract to reduce the rate of heat transfer to the hot side, while the fins in contact with the refrigerant can be extended to increase surface area or collisions, thereby distributing the heat load more efficiently. to the refrigerant. Thus, the mass heat transfer in hot spots can be balanced to colder spots, with a more uniform heat transfer from the exhaust gases to the refrigerant than in the case when static ribs are provided in one or both of the illustrated two paths or channels.

A coating or overlay can be provided along the surfaces that contact the fluid streams passing through one or more of the channels. Suitable coatings can be made of a material other than the support or base structure of the monolith, but still form a single structure (and therefore are part of the monolith). In one embodiment, the cover layer can be used to separate the fluid from the base structure. Thus, a basic aluminum structure can be susceptible to chemical dissolution upon contact with an alkaline or acidic fluid, so a chemically inert coating can be provided to prevent aluminum from contacting an acidic / alkaline fluid. In one embodiment, a catalyst (eg, platinum) may be incorporated into the coating to allow the exhaust gas stream to be catalyzed as it passes over the coating. In another embodiment, the coating may have a low surface energy and / or a smooth surface (i.e., a surface with a roughness below a threshold value) to, for example, reduce or control the pressure drop in the flow through the heat exchanger.

As with the coating, a post-surface finishing step can be performed on the heat exchanger. The appropriate post-machining will depend on the parameters for the particular application, however, in some embodiments, slurry washing may be used. Other suitable processes may include honing, grinding, superfinishing to alter the texture or roughness of the surface. It may be preferable to carry out the post-treatment by chemically altering the surface by methods such as acid washing, nitriding, carburizing, boriding, carbonitriding, and ferritic nitriding. In one embodiment, a material can be used to create an additive manufacturing element that is converted to another material during subsequent processing. Examples of such material are calcined material or ceramic / glaze, which are formed by heating the heat exchanger to a temperature sufficient to initiate the conversion process.

While the heat exchanger may be described as being made entirely by additive manufacturing processes, in at least one embodiment, a portion of the heat exchanger can be produced by other means, such as casting, machining, and / or a suitable manufacturing process. Then, the non-additively manufactured part can be combined with the monolithic part, which is obtained by the additive method and can be extended onto the base part. Over-molding of a plastic part is unsatisfactory, but a good example of combining two manufacturing processes to create one product. That is, the cast part can be combined with an additive part that can be built up on it. This part, obtained by an additive method, can span the cast part, or can only be attached to the side of the cast part.

The following is a description of one additive manufacturing process. Additive manufacturing processes enable the manufacture of components using three-dimensional (3D) information about a component, such as a 3D computer model of a component. Accordingly, a three-dimensional design model of the heat exchanger can be determined prior to fabrication. In this regard, a scan of a model or prototype of the heat exchanger may be performed to determine 3D information about the heat exchanger. As another example, it is possible to model a heat exchanger using a suitable computer-aided design (CAD) program to create a three-dimensional design model of the heat exchanger.

Each successive layer can have a thickness of, for example, in the range from about 10 to about 200 microns, however, the thickness can be selected based on parameters depending on the particular application, and have a value depending on the application. Therefore, when using the above-described additive molding methods, the heat transfer surfaces (eg walls) can have a thickness equal to the thickness of the corresponding layer of powder material (eg 10 µm) used during the addition molding process.

The heat exchanger can be a monolithic or a single piece of solid material. Under the monolithicity of products is meant that they may not contain components and / or compounds or contain fewer components and / or compounds in comparison with existing heat exchangers. The monolithic design clearly excludes molded, extruded or cast parts. Making the heat exchanger integral with additive manufacturing can improve the overall assembly process. For example, performing in one piece can reduce the number of individual parts to be assembled, thereby reducing assembly time and costs. In addition, existing problems such as those related to leakage, welding and connection quality between individual parts, as well as overall performance, can be reduced.

The described methods of additive manufacturing make it possible to obtain more complex and shaped shapes and contours of the heat exchanger. For example, a heat exchanger may have thin walls (less than 0.07 cm), narrow channels, and heat exchange elements. These elements can be relatively complex and shaped to maximize heat transfer and minimize the size or footprint of the heat exchanger. The additive manufacturing method allows for the manufacture of structures containing different materials and having specific heat transfer coefficients or desired surface textures, for example, to enhance or restrict the flow of fluid passing through the channel. The consistent, additive nature of the manufacturing process makes it possible for these channels and elements to be formed. As a result, the performance of the heat exchanger may differ from that of other heat exchangers.

Using an additive process, the resulting surface finish and channel size can improve fluid flow through the channels, improve heat transfer in

- 8 038501 channels, etc. For example, the surface finish can be adjusted (eg, the surface can be smoother or rougher) by selecting appropriate laser parameters during the additive process. A coarser finish can be obtained by increasing the laser scan speed or powder layer thickness, and a smoother finish can be obtained by decreasing the laser scan speed or powder layer thickness. The scan pattern and / or laser power can also be changed to change the surface finish in the selected area. It should be noted that a smoother surface can promote faster fluid passage through the heat exchanger duct, while a rougher surface can create turbulent fluid flow and increase heat transfer.

In one embodiment of the invention, the temperature control device comprises a housing. The specified device contains a monolithic central structure located inside the housing. The outer surface of the central structure defines at least a portion of the first channel. The inner surface of the central structure defines at least part of the second channel. The central structure contains a dividing wall that isolates the first flow through the first channel from the second flow through the second channel. The first channel may be in thermal contact with the second channel. The central structure contains one or more heat exchange elements, or fins, which are located in the first channel, the second channel, or in both of these channels. Heat transfer elements are characterized by their thickness and density of distribution. In this case, the central structure additionally contains a deformable component, the first end of which is attached to the housing structure, and the second end is attached to the dividing wall. In another embodiment, the deformable component attaches one dividing wall to another dividing wall. The deformable component does not move along the entire length of the channel, but only attaches the above dividing walls or body.

In one embodiment, the deformable component can have various shapes. Each shape may be better suited for different applications based on a number of criteria which, among many others, may include the material used, the length of the specified component, thermal and physical stresses in the component, or possibly the fluid passing in contact with the thermal component. In one embodiment, the deformable component can be non-linear and allows the central structure to bend and / or expand relative to the body.

In one embodiment, the thermal control device may comprise two or more different materials. These materials can be heterogeneous and not alloyed with each other. This can come in many different forms. Some examples of these forms are given below, but the possible options for implementation are not limited only to those listed in this document. These different materials can be superimposed one on top of the other with alternation in a pattern or in an arbitrary manner. The material can be used to coat the surfaces of the heat exchanger. The material can be a material added to a chemical or electrochemical process such as anodizing or the like. Materials can be mixed in the process of forming regions from different materials. These areas can range in size from less than a grain of sand to the size of the entire thermostatic control device. One example of such an implementation can be obtained by mixing a powder of different materials used to create a thermostatic control unit, if it is to be manufactured in an additive manner.

In one embodiment, two or more different materials may be used in the temperature control device. These materials are used in such a way that the first material can be in the first part and the second material can be in the second part of the heat exchanger body. These parts can be designed so that higher fatigue strength material can be used in areas or parts experiencing higher stresses, while more readily available material can be used in less critical areas or parts. Materials selected for different parts can also be used to balance local thermal efficiency. The material selected for one part may have a significantly higher thermal conductivity, and the material selected for the other part may have a significantly lower thermal conductivity. This can be done to reduce the local efficiency in areas of high thermal stress relative to other areas of the temperature control device, thereby equalizing the amount of heat transfer along the path of the fluid flow.

In one embodiment, these parts can be arranged in a thermostatic device in layers, with several parts having several materials. The first part and the second part can be different layers of the heat exchange element. The first material may have a coefficient of thermal expansion different from the coefficient of thermal expansion of the second material. In addition, the heat transfer elements can vary depending on the temperature of the element. Heat transfer elements can be wavy or non-planar. Both of the specified materials used in the heat transfer elements may differ from any other materials,

- 9 038501 used in the thermostatic block. The heat transfer elements can also form part of the wall separating the fluid flow. In this embodiment, the element can redirect the flow to different channels depending on the temperature of the fluids. In another embodiment, the heat exchange elements can be fins, and these fins can be adjusted staggered or non-staggered depending on the temperature of the fluid. In addition, thermally controlled heat exchange elements may or may not be implemented in the entire temperature control device. In addition, these elements may or may not behave the same at all locations in the device.

In one embodiment of the thermostatic control device, there may be a first and a second part. The first part can be the first section and the second part can be the second body section. The first stream or the second stream can pass first through the first part and then through the second part. At least some of the sections may not be made of the same material. Materials with higher fatigue strength or lower thermal conductivity can be used in sections with the highest temperature gradient of the fluid flow, while a more readily available material or material with higher thermal conductivity can be used in sections with a lower temperature gradient between flows.

In one embodiment, the dividing wall of the thermostatic control device delimits one or more paths. These paths form one channel. At least two paths need not be non-parallel to each other. Several paths may not be parallel to each other, which leads to the fact that the overall shape of the thermoregulatory device is curved and / or tortuous.

The device can limit two or more channels. In one embodiment, there is a first channel and a second channel. The first channel, the second channel, or both of these channels may differ from each other in one or more aspects. One difference may be the cross-sectional area along the path of their respective streams. The cross-sectional area of the channel may differ depending at least in part on parameters specific to a particular application. These parameters may include fluid type, flow rates, heat transfer rates, wall thickness, wall or heat exchanger materials, or fin material.

With regard to the cross-sectional area, depending on the location, there are first and second thicknesses. At least one of these thicknesses can range from about 0.0127 to about 0.0254 cm. A suitable thickness range may depend at least in part on the particular application. Suitable ranges for specific uses may be from about 0.0127 to about 0.0150 cm, from about 0.0150 to about 0.0170 cm, from about 0.0170 to about 0.0190 cm, from about 0.0190 to about 0.0210 cm, about 0.0210 to about 0.0230 cm, or about 0.0230 to about 0.0254 cm. The selection of the appropriate range can be made based on considerations related to the allowable pressure drop in the thermostatic device, flow properties the medium or fluids passing through the device, the required surface area of the device, the material of the ribs, the arrangement of the ribs, the required thermal efficiency, or the material of the walls of the device. These thicknesses characterize the thicknesses of the heat transfer elements. These elements can have many different shapes and, inter alia, can be projections, villi / tendrils, or elongated rib-like structures.

In one embodiment, there may be a first heat transfer element density and a second heat transfer element density. At least one of these densities may vary along at least one of the channels at different locations on the temperature control device. In some cases, depending on the application, the density can change discretely in one or more sections, in other cases the density can change gradually over at least a portion of the channel, or both types of change can occur along the same channel. The distribution density can range from about 2 to about 40 heat transfer elements / cm. This range can be subdivided into many different sub-ranges depending on the application of the temperature control unit. The most suitable distribution density range, or how the density differs, may depend at least in part on one or more of the following: cell materials, specific fluid used, cell thicknesses, cell configuration or shape, overall efficiency requirements, local requirements. the efficiency or allowable pressure drop of the fluid passing through the device. Changes in other aspects can also take place along the channel. For example, the ribs themselves can change, the angle of inclination of the ribs relative to the wall can change, and the density of the arrangement of the elements can also change, and all of these parameters can vary depending on each other. The ribs can have different density, spacing or orientation depending on their location along the path through which the flow passes.

The distribution density of the heat transfer elements can be relatively low in the portion of the heat exchanger with a relatively higher level of thermal stress. Conversely, the distribution density of the heat exchanger elements may be higher in the part where the thermal stress is lower. Thermal stress can be one or more of the following: cyclic heat load, absolute temperature fluctuations, temperature deviations outside a certain operating temperature range, or a combination of the above with increased pressure drops and / or vibrations.

In one embodiment, at least one heat exchange element or fin may not be perpendicular to the wall. At least one of the heat exchange elements can be located at an angle relative to the plane defined by the wall, and the value of the specified angle falls into many different ranges. A suitable range of angles may be from about 0.001 to less than 90 °. Depending on the application, the angle may range from about 0.001 ° to about 15 °, from about 16 ° to about 30 °, from about 31 ° to about 45 °, from about 46 ° to about 60 °, from about 61 ° to about 75 ° or from about 76 ° to less than 90 °. The particular angle may depend at least in part on the field of application and other related factors. Some of these factors may include the types of thermal fluid used in the various channels of the device, the thickness of the heat exchange elements, the density of the heat exchange elements, the allowable pressure drop across the temperature control unit, the required overall efficiency of the temperature control device, or the required local efficiency of the temperature control device, and the materials used for the formation of heat exchange elements.

It is possible to use a large number of heat exchange elements. In the direction of flow through the channel, a first heat exchange element may be disposed, offset from a second element located downstream of the first element. Thus, the elements can be staggered, thereby ensuring the destruction of the boundary layer of the flow at the wall and increasing the number of points of impact.

In one embodiment, one or more of the heat transfer elements may have a complex shape. A complex-shaped feature can be a non-planar rib. A suitable rib may have a curved, wavy, or pleated / corrugated shape. It can be attached to at least two walls that separate the fluid flow.

In one embodiment, the housing defines a first inlet region and a first outlet region. These areas are located at opposite ends of the first channel. The first inlet region may be located upstream of the first outlet region. The flow temperature in the first inlet region is higher than in the first outlet region. The density of the heat exchange elements in the first inlet region may be less than in the first outlet region. The housing may define a second inlet region and a second outlet region located at opposite ends of the second channel. The second inlet region may be located upstream of the second outlet region with respect to the second stream. The second passage in the first inlet region may have a higher volumetric flow rate, higher linear flow rate, or both, depending on the application, than in the first outlet region.

In one embodiment, the housing may define a sensor opening. This hole is for positioning a sensor or for positioning a plug when the sensor is not present. The housing may include at least a portion of an exhaust gas recirculation system, an oil cooler system, a radiator or fuel preheater system, an intercooler system, or a aftercooler system that may be coupled to the engine.

In one embodiment, the thermostatic control device comprises a housing. A monolithic central structure is located inside the body. The central structure may have an outer surface defining at least part of the first channel and an inner surface defining at least part of the second channel. The central structure contains a dividing wall that isolates the first flow through the first channel from the second flow through the second channel. The first channel may be in thermal contact with the second channel. The central structure contains one or more heat exchange elements, which are located in the first channel, the second channel, or in both of these channels. Heat transfer elements are characterized by their thickness and density of distribution. In addition, the central structure contains two or more different materials that are non-uniform and not alloyed with each other.

In one embodiment, the thermostatic control device comprises a housing. A monolithic central structure is located inside the body. The central structure may have an outer surface defining at least part of the first channel and an inner surface defining at least part of the second channel. The central structure contains a dividing wall that isolates the first flow through the first channel from the second flow through the second channel. The first channel may be in thermal contact with the second channel. The monolithic central structure has one or more ribs that are located in the first channel, the second channel, or in both of these channels. The ribs are complex. The monolithic central structure has a coating or surface layer which can be made of material other than the material of the main body of the central structure, the material of said one or more ribs, or material of both the central structure and the ribs.

Reference can be made in detail to embodiments of the invention, one or more examples of which are shown in the accompanying drawings. In the foregoing detailed description, reference numerals and letters are used to refer to elements shown in the drawings. Similar or similar designations in the drawings and description are used to refer to similar or similar elements.

As used herein, the words first, second, and third may be used interchangeably to distinguish one component from another and are not intended to denote the location or significance of individual components. The expressions upstream and downstream refer to the direction relative to the flow of the fluid in the fluid path. For example, an expression upstream denotes a direction indicating where a fluid flow comes from, and an expression downstream denotes a direction indicating where a fluid flow is going. As used herein, the expression "fluid" can mean a gas or a liquid. A suitable cooling fluid can be air and the cooled fluid can be lubricating oil. It is possible to use other types of fluids, liquid and gaseous. Other examples of fluids can be kerosene, gasoline, or diesel fuel. Other fluids can be hydraulic fluid, combustion gas, refrigerant, refrigerant mixtures, dielectric fluids for cooling electronic systems, water or water-based formulations, anti-freeze additives (for example, alcohol or glycol formulations), and other organic or inorganic heat transfer fluids or mixtures of fluids. In some applications, these fluids are capable of stable heat transfer at higher or lower temperatures.

In the foregoing description, the examples are used to disclose the invention, including the preferred embodiment, as well as to enable the invention to be practiced, including the manufacture and use of any devices or apparatus and the implementation of any provided methods, by a person skilled in the art. The scope of the invention is defined by the claims and may cover other examples obvious to those skilled in the art. Such other examples are intended to be within the scope of the claims if they contain structural elements that do not differ from those described in the literal text of the claims, or equivalent structural elements that differ slightly from those described in the literal text of the claims.

Claims (15)

CLAIM 1. Thermal control device (800) comprising a housing (802), a monolithic central structure (804) located inside said housing (802), and the outer surface (806) of said central structure (804) defines at least part of the first channel (808 ), and the inner surface (810) of said central structure (804) defines at least part of the second channel (812), while said central structure (804) comprises a dividing wall (820) designed to isolate the first flow passing through said first channel (808), from a second flow passing through said second channel (812), wherein said first channel (808) is in thermal contact with said second channel (812), while said central structure (804) contains one or more heat exchange elements (830), which are located in the specified first channel (808) or the specified second channel (812) or in both of the specified channels (808, 812) and the nature are formed by the thickness and density of their distribution, and the specified central structure (804) contains an elastic element (840) made with the possibility of expansion / compression, bending or bending under the action of a load, while the first end (842) of the specified elastic element (840) is connected to structure of the housing, and the second end (844) of the specified element (840) is connected to the specified dividing wall (820) with the possibility of bending and / or expansion of the specified central structure (804) relative to the specified housing (802). 2. Thermal control device according to claim 1, wherein said resilient element (840) is non-linear, and the body (802) comprises two or more different materials that are non-uniform and not doped with each other. 3. A thermal control device according to claim 2, wherein said two or more different materials are arranged so that the first material is in the first part and the second material is in the second part of said housing (802). 4. The thermal control device according to claim 3, wherein said first and second parts are different layers of a heat exchange element, wherein said first material has a coefficient - 12 038501 thermal expansion, different from the coefficient of thermal expansion of the specified second material, as a result of which the shape of the specified heat exchange element changes depending on its temperature. 5. The thermal control device of claim 3, wherein said first portion is a first section and said second portion is a second section of said housing (802), wherein said first stream or said second stream passes through said first portion prior to passing through the specified second part. 6. Thermostatic control device of claim 1, wherein said dividing wall (820) delimits a set of paths forming one channel, at least two of said paths being oriented and configured so that they are not parallel to each other. 7. Thermostatic control device according to claim 1, in which the cross-sectional area of said first channel (808), said second channel (812), or both said channels (808, 812) changes along the path of the corresponding flow, while the first thickness and / or the second thickness ranges from about 0.0127 to about 0.0254 cm. 8. The temperature control device according to claim 1, wherein the first density of the heat exchange elements and / or the second density of the location of the heat exchange elements vary along at least one channel at different locations of the temperature control device. 9. The thermal control device of claim 1, wherein the distribution density of the heat exchange elements is lowest in that portion of the heat exchanger where the thermal stress is relatively greater than in the portion with lower thermal stress. 10. The thermal control device of claim 1, wherein at least one of the heat exchange elements is angled with respect to a plane defined by said wall, said angle being in the range of about 0.001 to less than 90 °. 11. The thermal control device according to claim 1, wherein the heat exchange element is one of a set of heat exchange elements, wherein in the direction of flow passing through said channel, the first element of the set of heat exchange elements is disposed, offset from the second heat exchange element located downstream from the specified first element, ensuring the arrangement of the heat exchange elements in a checkerboard pattern. 12. The thermal control device of claim 1, wherein the at least one heat exchange element has a complex shape. 13. Thermostatic control device of claim 1, wherein said housing (802) defines a first inlet region and a first outlet region located at opposite ends of said first channel, said first inlet region upstream of said first outlet region, wherein the flow temperature in said first inlet region is higher than in said first outlet region, and the density of the heat exchange elements in said first inlet region is less than in said first outlet region. 14. Thermostatic control device of claim 1, wherein the at least one heat transfer element is surface-finished, said housing (802) defining a sensor opening for inserting the sensor. 15. Thermostatic control device according to claim 1, wherein said housing (802) comprises at least part of an exhaust gas recirculation system, an oil cooler system, a radiator system or a fuel heater system, an intercooler system or a aftercooler system that is connected to the engine, when the heat exchange elements are fins.