Systems and methods for heat exchanger tubes having internal flow features
A support form defining a longitudinal axis is provided. The support form includes a first section, a second substantially solid section, and at least one flow feature form. The first section includes a plurality of unit cells of a first material joined together to form a lattice. The second section includes a second material and surrounds the first section. The at least one flow feature form is defined in the second section and is configured to generate a flow feature on a heat exchanger tube formed by plating the support form.
1. A support form defining a longitudinal axis, said support form comprising:
a first section comprising a plurality of unit cells of a first material joined together to form a lattice;
a second solid section comprising a second material, said second section surrounding said first section; and
at least one flow feature form defined in said second section, said at least one flow feature form comprising a negative mold, wherein said support form is configured to form a heat exchanger tube by plating said support form, and wherein said at least one flow feature form is configured to yield a positive cast of a flow feature on the heat exchanger tube formed by plating said support form.
2. The support form in accordance with claim 1 , wherein said at least one flow feature form comprises a three-dimensional flow feature form having a varying cross-section along the longitudinal axis of said support form.
3. The support form in accordance with claim 1 , wherein said first section is coupled to said second section.
4. The support form in accordance with claim 1 , wherein said first material and said second material are the same.
5. The support form in accordance with claim 1 , wherein said at least one flow feature form comprises a transverse flow feature form that extends from a first portion of second section to a second portion of said second section.
6. The support form in accordance with claim 5 , wherein said transverse flow feature form is at least one of a through-passageway form and a flow straightener form.
7. The support form in accordance with claim 1 , wherein said support form has a cross-sectional shape that is of one triangular, rectangular, circular, and elliptical.
8. The support form in accordance with claim 1 further comprising a first end comprising a first connector configured to engage a corresponding connector of a second support form to couple said second support form to said support form to form a continuous multiple-form support form.
9. The support form in accordance with claim 1 , wherein said at least one flow feature form comprises a heat exchanger fin form that extends outward from said second section, said heat exchanger fin form comprising a negative mold configured to yield a positive cast of a heat exchanger fin.
10. The support form in accordance with claim 1 , wherein said at least one flow feature form comprises a mounting feature form that extends outward from said second section, said mounting feature form comprising a negative mold configured to yield a positive cast of a mounting feature.
11. The support form of claim 1 , wherein the at least one flow feature form further comprises:
a base;
an apex; and
at least one wall extending from the base toward the apex.
12. The support form of claim 8 , further comprising:
a plurality of barbs extending from the first connector; and
a retention extension disposed on the second connector,
wherein the plurality of barbs are configured to be received against the retention extension.
13. The support form of claim 1 , wherein the support form is configured to be removed from the heat exchanger tube without deformation of the heat exchanger tube.
14. The support form of claim 2 , wherein the varying cross-section varies with respect to a width and a height along the longitudinal axis of said support form.