PARTIALLY ADDITIVELY MANUFACTURED HEAT EXCHANGER
A heat exchanger includes a base structure, and a plurality of layers stacked on the base structure. Each layer includes multiple additively manufactured ribs extending from one of the base structure. A foil layer is disposed across the additively manufactured ribs such that a plurality of channels are defined within each layer.
1 . A heat exchanger comprising:
a base structure; and
a plurality of layers stacked on said base structure, each layer including a plurality of additively manufactured ribs extending from one of the base structure and an adjacent layer of the plurality of layers, at least one of the additively manufactured ribs having a tapered cross section having a smallest width at one of a base of the additively manufactured rib and a mid-section of the additively manufactured rib, and a foil layer disposed across said additively manufactured ribs such that a plurality of channels are defined within each layer.
2 . The heat exchanger of claim 1 , wherein the plurality of additively manufactured ribs in at least one layer of said plurality of layers are skewed relative to the plurality of additively manufactured ribs in an adjacent layer.
3 . The heat exchanger of claim 1 , wherein the plurality of additively manufactured ribs in at least one layer of said plurality of layers are aligned with the plurality of additively manufactured ribs in an adjacent layer.
4 . The heat exchanger of claim 1 , wherein the foil layer has a thickness in the range of 15-35 microns.
5 . The heat exchanger of claim 4 , wherein the foil layer has a thickness of approximately 25 microns.
6 . The heat exchanger of claim 1 , wherein each of said additively manufactured ribs has a height in the range of 50-200 microns.
7 . The heat exchanger of claim 1 , wherein each of said foil layers includes micro corrugations.
8 . The heat exchanger of claim 1 , wherein each of said foil layers includes macro corrugations.
9 . The heat exchanger of claim 8 , wherein each of said foil layers includes micro corrugations.
10 . The heat exchanger of claim 1 , wherein the heat exchanger is one of an air-air heat exchanger, an air-fuel heat exchanger, an air-oil heat exchanger, and a fuel-oil heat exchanger.
11 . (canceled)
12 . The heat exchanger of claim 1 , wherein a smallest width of each of said additively manufactured ribs is a base of the rib.
13 . (canceled)
14 . The heat exchanger of claim 1 , wherein a smallest width of each of said additively manufactured ribs is at a mid-section of each of said ribs.
15 - 17 . (canceled)
16 . The heat exchanger of claim 1 , wherein each additively manufactured rib in a layer of the plurality of layers has the same cross section as each other additively manufactured rib in the layer.