阅读说明：本技术 具有带圆形单位单元进口的三维晶格结构的热交换器以及在热交换器的三维晶格结构中形成圆形单位单元进口的方法 (Heat exchanger having three-dimensional lattice structure with circular unit cell inlets and method of forming circular unit cell inlets in three-dimensional lattice structure of heat exchanger ) 是由 朗尼·雷·小斯图尔特 塞缪尔·诺亚·米勒 于 2019-07-10 设计创作，主要内容包括：提供具有限定重复单位单元的三维晶格(104)的多个一体形成的连续单位单元的热交换器(100),以及在热交换器(100)的三维晶格(104)结构中减少压降的方法。多个一体形成的连续单位单元包括多个路径单元(200)和多个部分单位单元(304)。多个路径单元(200)具有包括内部和外部路径单元表面(210)的固体域(202),内部和外部路径单元表面(210)分别连续地限定第一和第二分叉流体域(204),(206),分别用于第一流体(138)和第二流体(144)流经多个路径单元(200)。多个部分单位单元(304)可将部分相移引入重复单位单元的三维晶格(104),使得第一流体(138)域包括第一圆形单位单元进口(306),并且第二流体(144)域包括第二圆形单位单元进口(308)。(A heat exchanger (100) having a plurality of integrally formed continuous unit cells defining a three-dimensional lattice (104) of repeating unit cells and a method of reducing pressure drop in a three-dimensional lattice (104) structure of a heat exchanger (100) are provided. The plurality of integrally formed continuous unit cells includes a plurality of path cells (200) and a plurality of partial unit cells (304). The plurality of path elements (200) has a solid domain (202) including inner and outer path element surfaces (210), the inner and outer path element surfaces (210) continuously defining first and second divergent fluid domains (204), (206), respectively, for the first fluid (138) and the second fluid (144), respectively, to flow through the plurality of path elements (200). The plurality of partial unit cells (304) may introduce a partial phase shift into the three-dimensional lattice (104) of repeating unit cells such that the first fluid (138) domain includes a first circular unit cell inlet (306) and the second fluid (144) domain includes a second circular unit cell inlet (308).)

1. A heat exchanger (100), comprising:

a plurality of integrally formed continuous unit cells defining a three-dimensional lattice (104) of repeating unit cells, the plurality of integrally formed continuous unit cells including a plurality of path cells (200) having a solid domain (202), the solid domain (202) comprising:

an inner path unit surface (208), the inner path unit surface (208) continuously defining a first diverging fluid domain (204) for a first fluid (138) to follow a first diverging serpentine flow channel (108) from a first fluid inlet region (116) to a first fluid outlet region (120) through the plurality of path units (200); and

an outer path unit surface (210), the outer path unit surface (210) continuously defining a second bifurcated fluid domain (206) for a second fluid (144) to follow a second bifurcated serpentine flow channel (108) from a second fluid inlet region (128) to a second fluid outlet region (132) through the plurality of path units (200);

wherein the plurality of integrally formed continuous unit cells additionally comprises a plurality of partial unit cells (304) conforming to the solid domain (202), the plurality of partial unit cells (304) introducing a partial phase shift into the three-dimensional lattice (104) of repeating unit cells such that the first fluid (138) domain comprises a first circular unit cell inlet (306) and the second fluid (144) domain comprises a second circular unit cell inlet (308).

2. The heat exchanger (100) of claim 1, wherein at least a portion of the partial unit cells (304) are disposed at the first fluid inlet region (116) of the three-dimensional lattice (104).

3. The heat exchanger (100) of claim 2, wherein at least a portion of the partial unit cells (304) are disposed adjacent the first fluid inlet plenum (114).

4. The heat exchanger (100) according to any one of the preceding claims, wherein at least a portion of the partial unit cells (304) is disposed at the second fluid inlet region (128) of the three-dimensional lattice (104).

5. The heat exchanger (100) of claim 4, wherein at least a portion of the partial unit cells (304) are disposed adjacent to the first fluid inlet plenum (114).

6. The heat exchanger (100) according to any of the preceding claims, wherein at least a portion of the partial unit cells (304) is disposed at an intermediate region of the three-dimensional lattice (104).

7. The heat exchanger (100) according to any of the preceding claims, wherein at least a part of the partial unit cells (304) is a partial path cell (200).

8. The heat exchanger (100) of any of the preceding claims, wherein the partial phase shift ranges from a phase of 1/16 to a phase of 15/16.

9. The heat exchanger (100) of any of the preceding claims, wherein the partial phase shift is a phase of 1/2.

10. The heat exchanger (100) according to any of the preceding claims, wherein the first circular unit cell inlet (306) and/or the second circular unit cell inlet (308) exhibit a drag coefficient K ranging from 0.02 to 0.4.

11. The heat exchanger (100) according to any of the preceding claims, wherein the first circular unit cell inlet (306) and/or the second circular unit cell inlet (308) exhibit a drag coefficient K below 0.4.

12. The heat exchanger (100) of any of the preceding claims, further comprising:

a body (102), the body (102) circumferentially surrounding the plurality of integrally formed continuous unit cells.

13. The heat exchanger (100) of any of the preceding claims, further comprising:

a first inlet manifold (110) and a first outlet manifold (124), the first inlet manifold (110) defining a first inlet plenum (114), the first inlet plenum (114) being in fluid communication with an inlet region of the first bifurcated fluid region (204), the first outlet manifold (124) defining a first outlet plenum (118), the first outlet plenum (118) being in fluid communication with an outlet region of the first bifurcated fluid region (204); and/or

A second inlet manifold (122) and a second outlet manifold (124), the second inlet manifold (122) defining a second inlet plenum (126), the second inlet plenum (126) in fluid communication with an inlet region of the second bifurcated fluid region (206), the second outlet manifold (124) defining a second outlet plenum (130), the second outlet plenum (130) in fluid communication with an outlet region of the second bifurcated fluid region (206).

14. The heat exchanger (100) of any of the preceding claims, further comprising:

a plurality of baffle units (250), the plurality of baffle units (250) being integrally formed among the plurality of path units (200) and conforming to the three-dimensional lattice (104), the plurality of baffle units (250) having a solid domain (202), the solid domain (202) comprising:

one or more first bifurcated path blinders (254), the one or more first bifurcated path blinders (254) together providing one or more first bifurcated path baffles (300), each of the first bifurcated path baffles (300) continuously defining a first boundary of the first bifurcated fluid region (204); and/or

One or more second bifurcated path blinders (256), the one or more second bifurcated path blinders (256) together providing one or more second bifurcated path baffles (302), each of the second bifurcated path baffles (302) continuously defining a second boundary of the second bifurcated fluid region (206).

15. A method of reducing pressure drop at an inlet of a three-dimensional lattice structure of a heat exchanger, the method comprising:

forming a plurality of integrally formed continuous unit cells defining a three-dimensional lattice of repeating unit cells, the plurality of integrally formed continuous unit cells including a plurality of path cells having a solid domain comprising:

an internal path unit surface continuously defining a first diverging fluid region for a first fluid to flow through the plurality of path units following a first diverging serpentine flow path from a first fluid inlet region to a first fluid outlet region; and

an outer path unit surface continuously defining a second bifurcated fluid region for a second fluid to flow through the plurality of path units following a second bifurcated serpentine flow channel from a second fluid inlet region to a second fluid outlet region;

wherein forming the plurality of integrally formed continuous unit cells comprises forming a plurality of partial unit cells that introduce a partial phase shift into the three-dimensional lattice of repeating unit cells such that the first fluid domain comprises a first circular unit cell inlet and the second fluid domain comprises a second circular unit cell inlet.

Technical Field

The present disclosure relates generally to heat exchangers having a three-dimensional lattice structure with circular unit cell inlets and methods of forming circular unit cell inlets in the three-dimensional lattice structure of the heat exchanger.

Background

The heat exchanger may be coupled to the fluid flow at an inlet manifold defining an inlet plenum at which the fluid enters the heat exchanger. A typical shell and tube heat exchanger includes a tube sheet, which is a panel at the interface between the inlet plenum and the tube bundle that directs fluid into the tubes of the heat exchanger. The flow path from the inlet plenum into the tube bundle typically exhibits a relatively abrupt transition. Such abrupt transitions may result in significant shear stress and corresponding pressure drop, which may affect process design considerations. Similar abrupt transitions may exist for previous heat exchangers that utilized a three-dimensional lattice structure rather than a tube bundle.

Heat exchangers sometimes utilize baffles to direct or regulate fluid flow. A typical shell and tube heat exchanger may include a baffle on the shell side of the heat exchanger that directs the shell side fluid through the flow channels defined by the baffle. The baffles may also be used to support the tube bundle within the heat exchanger shell. Such baffles are typically made from a panel having a plurality of holes corresponding to each tube in the tube bundle. The holes of the panels are mounted on the heat exchanger tubes and the panels are welded in place.

The manufacturing process of baffles of this nature can be complex and time consuming, and therefore heat exchangers typically have a rather simple baffle construction. In addition, when the baffles are installed and welded to the tubes, the heat exchanger tubes are prone to damage and may cause leaks or stress points due to manufacturing errors such as wrong welds, resulting in poor performance, cross contamination of fluids or structural failure. Furthermore, due to the complexity of manufacturing, particularly for heat exchangers having multiple tubes, the tube side of the heat exchanger is typically free of baffles. The three-dimensional lattice structure can replace a tube bundle. However, the above-mentioned disadvantages may become more pronounced when baffles are added to the three-dimensional lattice structure, since the lattice structure may have a more complex configuration relative to a typical tube bundle.

Accordingly, there is a need for a heat exchanger having an improved inlet plenum and an improved baffle. In addition, there is a need for methods of reducing the pressure drop of the fluid entering the three-dimensional lattice of the heat exchanger, and for improved methods of forming baffles in the heat exchanger.

Disclosure of Invention

Aspects and advantages will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the presently disclosed subject matter.

In one aspect, the present disclosure includes a heat exchanger having a plurality of integrally formed continuous unit cells defining a three-dimensional lattice of repeating unit cells, wherein the plurality of integrally formed continuous unit cells includes a plurality of partial unit cells. The plurality of integrally formed continuous unit cells includes a plurality of path cells. The plurality of path elements have solid domains including inner path element surfaces continuously defining first divergent fluid domains for the first fluid to flow through the plurality of path elements and outer path element surfaces continuously defining second divergent fluid domains for the second fluid to flow through the plurality of path elements.

The first bifurcated flow field may be constructed and arranged such that the first fluid flows through the plurality of path units following a first bifurcated flow passage from the first fluid inlet region to the first fluid outlet region. The second bifurcated fluid region may be constructed and arranged such that the second fluid flows through the plurality of path units following a second bifurcated flow passage from the second fluid inlet region to the second fluid outlet region. The plurality of integrally formed continuous unit cells may additionally include a plurality of partial unit cells conforming to the solid domain. The plurality of partial unit cells may introduce a partial phase shift into the three-dimensional lattice of repeating unit cells such that the first fluid domain comprises a first circular unit cell inlet and the second fluid domain comprises a second circular unit cell inlet.

In another aspect, the present disclosure includes a heat exchanger having a plurality of integrally formed continuous unit cells including a plurality of path cells and a plurality of baffle units integrally formed among the plurality of path cells. The plurality of path elements have solid domains including inner path element surfaces continuously defining first divergent fluid domains for the first fluid to flow through the plurality of path elements and outer path element surfaces continuously defining second divergent fluid domains for the second fluid to flow through the plurality of path elements. The plurality of baffle units have a solid body domain including one or more first bifurcation path blind plates (blids) that together provide one or more first bifurcation path baffles and/or one or more second bifurcation path blind plates that together provide one or more second bifurcation path baffles. Each first bifurcated path baffle contiguously defines a first boundary of a first bifurcated fluid domain, and each second bifurcated path baffle contiguously defines a second boundary of a second bifurcated fluid domain.

In some embodiments, the inner path unit surfaces of the plurality of path units together with the one or more first divergent path baffles define first divergent flow channels for the first fluid to flow through the first divergent fluid domain, and the outer path unit surfaces of the plurality of path units together with the one or more second divergent path baffles define second divergent flow channels for the second fluid to flow through the second divergent fluid domain. The first bifurcated flow passage may include a first flow orientation and the second bifurcated flow passage may include a second flow orientation. The first flow orientation may be different from the second flow orientation.

In another aspect, the present disclosure includes a method of reducing pressure drop at an inlet of a three-dimensional lattice structure of a heat exchanger. An example method includes forming a plurality of integrally formed continuous unit cells defining a three-dimensional lattice of repeating unit cells including a plurality of path cells. The plurality of path elements may be formed to have solid domains including inner path element surfaces continuously defining first divergent fluid domains for the first fluid to flow through the plurality of path elements and outer path element surfaces continuously defining second divergent fluid domains for the second fluid to flow through the plurality of path elements.

The first bifurcated fluid region may be formed to have a configuration and arrangement such that the first fluid flows through the plurality of path units following the first bifurcated flow passage from the first fluid inlet region to the first fluid outlet region. The second bifurcated fluid region may be formed to have a configuration and arrangement such that the second fluid flows through the plurality of path units following the second bifurcated flow passage from the second fluid inlet region to the second fluid outlet region. In some embodiments, forming a plurality of integrally formed continuous unit cells may include forming a plurality of partial unit cells. The plurality of partial unit cells may be formed to introduce a partial phase shift into the three-dimensional lattice of repeating unit cells such that the first fluid domain comprises a first circular unit cell inlet and the second fluid domain comprises a second circular unit cell inlet.

In another aspect, the present disclosure includes a method of forming baffles in a three-dimensional lattice structure of a heat exchanger. An exemplary method includes forming a plurality of integrally formed continuous unit cells defining a three-dimensional lattice of repeating unit cells. Forming the plurality of integrally formed continuous unit cells includes forming a plurality of path cells, and integrally forming a plurality of barrier cells among the plurality of path cells. The plurality of path elements may be formed to have solid domains including inner path element surfaces continuously defining first divergent fluid domains for the first fluid to flow through the plurality of path elements and outer path element surfaces continuously defining second divergent fluid domains for the second fluid to flow through the plurality of path elements. The plurality of baffle units may be formed to have a solid domain including one or more first divergent path baffles and/or one or more second divergent path baffles. Each of the first divergent path baffles may be formed to continuously define a first boundary of the first divergent fluid domain, and each of the second divergent path baffles may be formed to continuously define a second boundary of the second divergent fluid domain.

These and other features, aspects, and advantages will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate exemplary embodiments and together with the description, serve to explain certain principles of the presently disclosed subject matter.

Drawings

A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures. Wherein:

FIG. 1 schematically depicts an exemplary heat exchanger within which a plurality of integrally formed, continuous unit cells are disposed that together define a three-dimensional lattice of repeating unit cells;

2A-2H schematically depict exemplary unit cells, wherein the unit cells depicted in FIGS. 2A and 2B are pathway cells and the unit cells depicted in FIGS. 2C-2H are baffle cells;

3A-3C schematically depict an exemplary three-dimensional lattice of repeating unit cells;

FIG. 4 shows an exemplary inlet geometry for a unit cell and an exemplary drag coefficient corresponding to the exemplary inlet geometry;

5A-5C schematically depict an exemplary partial unit cell and a corresponding circular unit cell inlet to a three-dimensional lattice of a first fluid; and

fig. 6A-6C schematically depict an exemplary path cell and corresponding circular unit cell inlets to a three-dimensional lattice of a second fluid.

Repeat use of reference characters in the present specification and drawings is intended to represent same or analogous features or elements of the present disclosure.

Detailed Description

Reference will now be made in detail to exemplary embodiments of the presently disclosed subject matter, one or more examples of which are illustrated in the accompanying drawings. Each example is provided by way of explanation and should not be construed as limiting the disclosure. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present disclosure without departing from the scope or spirit of the disclosure. For instance, features illustrated or described as part of one embodiment, can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present disclosure cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.

It should be understood that the terms "upstream" and "downstream" refer to relative directions with respect to fluid flow in the fluid path. For example, "upstream" refers to the direction from which the fluid flows, and "downstream" refers to the direction to which the fluid flows. It should also be understood that terms such as "top," "bottom," "outward," "inward," and the like are words of convenience and should not be construed as limiting terms. As used herein, the terms "first," "second," and "third" may be used interchangeably to distinguish one element from another, and are not intended to denote the position or importance of the various elements. The terms "a" and "an" do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item.

Here and throughout the specification and claims, range limitations are combined and interchanged, and unless context or language indicates otherwise, such ranges are identified and include all the sub-ranges contained therein. For example, all ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other.

Approximating language, as used herein throughout the specification and claims, is applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as "about", "approximately" and "substantially", are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value, or the precision of a method or machine for constructing or manufacturing the component and/or system.

The present disclosure generally provides heat exchangers having a three-dimensional lattice structure with baffle units. An exemplary heat exchanger includes a plurality of integrally formed continuous unit cells defining a three-dimensional lattice of repeating unit cells. The integrally formed continuous unit cell includes a plurality of path cells and a plurality of barrier cells. The path unit and the barrier unit conform to a three-dimensional lattice, and the barrier unit is integrally formed among the path unit. The present disclosure additionally includes a method of forming baffles in a three-dimensional lattice structure of a heat exchanger.

The presently disclosed heat exchanger may provide improved manufacturability. For example, a three-dimensional lattice can be modeled as an array of integrally formed continuous unit cells that together define a three-dimensional lattice of repeating unit cells. The three-dimensional lattice structure can be quickly and accurately fabricated in any desired size, shape, or configuration, and any desired number or combination of unit cells, for example, using additive manufacturing techniques. The arrangement of the baffle units within the three-dimensional lattice can be modified without changing the configuration of the three-dimensional lattice. In this way, a wide variety of flow channels can be provided, starting from the same three-dimensional lattice configuration. For example, the flow channels can be customized for a particular application without changing the configuration of the three-dimensional lattice.

The flow channels may be selected to provide desired heat transfer properties, which may provide improved heat transfer. For example, the baffle unit may provide an increased effective length of the heat exchanger, while the partial path unit and the corresponding circular unit cell inlet may provide a reduced pressure loss. In addition, the baffle units may provide additional structural support to the three-dimensional lattice. Baffle units may be provided in the three-dimensional lattice in any desired configuration to allow each separate fluid flowing through the three-dimensional lattice structure of the heat exchanger to follow its own independent flow channel. The plurality of baffle units may define flow channels for one or more fluids flowing through the three-dimensional lattice.

The path cell may include a partial path cell that introduces a partial phase shift into the three-dimensional lattice of repeating unit cells, which allows the repeating unit cells to include circular unit cell inlets to both the first fluid domain and the second fluid domain. Such a circular unit cell inlet reduces or minimizes the pressure loss of the fluid entering the unit cell according to a resistance coefficient K corresponding to the inlet geometry of the unit cell.

The presently disclosed heat exchangers and three-dimensional lattice structures and corresponding unit cells can be used in any desired setting. As an example, the presently disclosed heat exchanger and three-dimensional lattice structure may be used in conjunction with a turbine or with an electric machine. Some examples of turbines and/or motors that may be utilized include aircraft, ships, motor vehicles, power generation facilities, manufacturing facilities, industrial machinery, and the like. In the case of an aircraft, the turbine may take the form of a turbofan engine, and an electric machine may be used to power such a turbine engine. Such aircraft may include commercial, military, or civilian aircraft, as well as unmanned aircraft, such as drones, electric rotorcraft, telecontrolled aircraft, and the like. It will be understood that the presently disclosed heat exchanger and three-dimensional lattice structure and corresponding unit cells can be used in many other settings and it is intended that the presently disclosed heat exchanger and three-dimensional lattice structure and corresponding unit cells can be implemented in any setting without departing from the scope or spirit of the present disclosure.

Various embodiments of the present disclosure will now be described in more detail. Referring to FIG. 1, an exemplary heat exchanger 100 is shown. The heat exchanger 100 includes a body 102 with a plurality of integrally formed continuous unit cells (fig. 2A-2H) disposed within the body 102 that together define a three-dimensional lattice 104 of repeating unit cells (fig. 3A-3C). The heat exchanger 100 includes paths for at least two fluids to flow through the three-dimensional lattice 104 of repeating unit cells. The illustrated embodiment includes two paths; however, it will be understood that additional paths may be provided without departing from the spirit or scope of the present disclosure. In fact, any desired number of paths may be provided, including three, four, five, or more paths. As shown, the first flow channels 106 allow a first fluid to flow through the three-dimensional lattice 104 of repeating unit cells, and the second flow channels 108 allow a second fluid to flow through the three-dimensional lattice 104 of repeating unit cells. As described herein, the first flow channel 106 includes a first bifurcated fluid region through which the first fluid flows, and the second path includes a second bifurcated fluid region through which the second fluid flows.

The heat exchanger 100 may include one or more inlet and/or outlet manifolds operatively coupled to or integrally formed with the body 102 of the heat exchanger. As shown, the first fluid inlet manifold 110 and the first fluid outlet manifold 112 may be operatively coupled to the body 102 of the heat exchanger 100 or integrally formed with the body 102 of the heat exchanger 100. The interior surface of the first fluid inlet manifold 110 defines a first fluid inlet plenum 114 in fluid communication with a first fluid inlet region 116 of the first divergent fluid region. The interior surface of the first fluid outlet manifold 112 defines a first fluid outlet plenum 118 in fluid communication with a first fluid outlet region 120 of the first bifurcated fluid domain. Additionally, a second fluid inlet manifold 122 and a second fluid outlet manifold 124 are operatively coupled to or integrally formed with the body 102 of the heat exchanger 100. The interior surface of the second fluid inlet manifold 122 defines a second fluid inlet plenum 126 in fluid communication with a second fluid inlet region 128 of the second bifurcated fluid region. The interior surface of the second fluid outlet manifold 124 defines a second fluid outlet plenum 130 in fluid communication with a second fluid outlet region 132 of the second bifurcated fluid domain.

The heat exchanger 100 may be in fluid communication with a first fluid source 134 and/or a first fluid destination 136, the first fluid source 134 and/or the first fluid destination 136 provided, for example, by one or more conduits or the like operatively coupled to the heat exchanger 100 or integrally formed with the heat exchanger 100, such as provided by the first fluid inlet manifold 110 and the first fluid outlet manifold 112, respectively. The first fluid source 134 provides a first fluid 138 to the heat exchanger 102, and the first fluid 138 flows through the first bifurcated fluid domain as described herein. After exiting heat exchanger 102, first fluid 138 may flow to first fluid destination 136. Likewise, the heat exchanger 100 may be in fluid communication with a second fluid source 140 and/or a second fluid destination 142, the second fluid source 140 and/or the second fluid destination 142 being provided, for example, by one or more conduits or the like operatively coupled to the heat exchanger 100 or integrally formed with the heat exchanger 100, such as by the second fluid inlet manifold 122 and the second fluid outlet manifold 124, respectively. The second fluid source 140 provides a second fluid 144 to the heat exchanger 102, the second fluid 144 flowing through a second bifurcated fluid domain as described herein. After exiting heat exchanger 102, second fluid 144 may flow to second fluid destination 142.

First fluid 138 may be a process fluid, such as a lubricant and/or a coolant. Such process fluids may be used, for example, to lubricate and/or cool an engine or an electric machine, such as a turbofan engine. The second fluid 144 may be a coolant, such as a liquid or air. For example, a first fluid 138, such as a process fluid, may be cooled using, for example, a coolant. In the exemplary embodiment, first fluid 138 is a liquid coolant that is used to extract heat from a turbofan engine or motor, and second fluid 144 is a liquid or air that is used to cool first fluid 138.

Turning now to fig. 2A-2H, an exemplary unit cell of the three-dimensional lattice 104 will be described. As mentioned, the plurality of integrally formed continuous unit cells define a three-dimensional lattice 104 of repeating unit cells. The unit cell comprises a three-dimensional space defined by at least four perimeter planes representing individual repeating units of the three-dimensional lattice 104. The perimeter plane of the unit cell includes a two-dimensional plane corresponding to a portion of the perimeter of the three-dimensional space encompassed by the unit cell. The unit cells may have any shape, size, or geometry corresponding to the individual repeating units of the three-dimensional lattice. The unit cells that make up the three-dimensional lattice 104 need not each have the same shape, size, or geometry. Indeed, it will be understood that the three-dimensional lattice 104 of repeating unit cells may include a repeating pattern or combination of unit cells having any desired shape, size, or geometric combination. Although a portion of the unit cells may be included in the three-dimensional lattice 104, the periphery of the three-dimensional lattice 104 may be identified by the presence of a repeating pattern of unit cells. By way of example, portions of the unit cells may be included as or near the periphery of the three-dimensional lattice 104, as or near baffle cells, or elsewhere throughout the three-dimensional lattice 104. For purposes of this disclosure, structures that deviate from the repeating pattern of unit cells are not considered to be part of the three-dimensional lattice 104. This includes peripheral structures such as the body 102 of the heat exchanger and internal structures that face away from the repeating pattern of unit cells.

The unit cell may be divided into one or more unit cell domains. The unit cell domain may be a solid domain or a fluid domain. The illustrated embodiment includes two fluid domains separated by a solid domain; however, it will be understood that additional fluid domains may be provided without departing from the spirit or scope of the present disclosure. For each additional fluid domain, an additional solid domain will be provided to separate the additional fluid domain from the other fluid domains. For example, a unit cell may comprise three fluid domains and two solid domains, or four fluid domains and three solid domains, and so on. In fact, any desired number of domains may be provided. The solid domains of the unit cell may be completely solid, or the hollow space may be located within the solid domain (i.e., isolated from the fluid domain). The hollow spaces located within the solid domains may reduce the overall weight of the three-dimensional lattice structure.

The unit cell may be a path cell or a barrier cell. The manner in which the unit cell is divided into unit cell domains determines whether the unit cell is a path cell or a barrier cell. Fig. 2A and 2B show an exemplary path unit 200, and fig. 2C-2H show an exemplary baffle unit 250. The unit cell includes at least four perimeter planes. As shown in fig. 2A-2H, a unit cell may include six perimeter planes, and the six perimeter planes may be oriented orthogonal to X, Y or the Z-axis, respectively. It will be understood that the unit cell may include any desired number of perimeter planes, and the unit cell may take the form of any desired polyhedron. Additionally, it will be understood that the perimeter plane may be configured to have any desired orientation.

Referring to fig. 2A and 2B, the path cell 200 includes those unit cells of the three-dimensional lattice 104 having solid domains 202, the solid domains 202 defining at least two separate, diverging fluid domains through which fluid may flow up or through each perimeter plane of the unit cell. The path unit 200 includes at least four perimeter planes. As shown in fig. 2A and 2B, the path unit 200 may include six perimeter planes. The six perimeter planes may be oriented orthogonal to X, Y or the Z-axis, respectively. The path cell 200 includes a solid body region 202 that separates and defines a plurality of diverging fluid regions. The bifurcated fluid domains have bifurcations or branches that allow fluid to flow in multiple directions throughout the three-dimensional lattice 104. It will be appreciated that any number of bifurcations or branches may be provided. The configuration and arrangement of such bifurcated fluid domains may be defined by the configuration and arrangement of the solid domains 202 that constitute respective unit cells of the three-dimensional lattice 104.

As shown, the path cell 200 includes a solid body region 202 defining a first bifurcated fluid region 204 and a second bifurcated fluid region 206. The first divergent fluid field 204 is divergent such that the first fluid may flow through each perimeter plane of the path unit 200. As shown, the solid domain 202 has an inner path element surface 208 and an outer path element surface 210, the inner path element surface 208 defining the first divergent fluid domain 204 and the outer path element surface 210 defining the second divergent fluid domain 206. The solid domain 202 may be completely solid or may have a hollow space between an inner path element surface 208 and an outer path element surface 210.

The first divergent fluid field 204 is divergent such that the first fluid 138 may flow through each perimeter plane of the path cell 200. As shown, the first bifurcated fluid domain 204 includes paths that diverge in three directions (e.g., first X-paths 212 with first and second perimeter planes having orthogonal orientations thereto, first Y-paths 214 with third and fourth perimeter planes having orthogonal orientations thereto, and first Z-paths 216 with fifth and sixth perimeter planes having orthogonal orientations thereto). A plurality of integrally formed continuous-path units 200, each having an interior-path-unit surface 208, may together continuously define a first divergent fluid domain 204 for the first fluid 138 to flow through the plurality of path units 200.

The second bifurcated fluid region 206 is bifurcated so that the second fluid 144 can flow through each peripheral plane of the path unit 200. As shown, the second bifurcated fluid region 206 includes paths that diverge in three directions (e.g., a second X-path 218 with which the first and second perimeter planes have an orthogonal orientation, a second Y-path 220 with which the third and fourth perimeter planes have an orthogonal orientation, and a second Z-path 222 with which the fifth and sixth perimeter planes have an orthogonal orientation). The plurality of integrally formed continuous path elements 200, each having an outer path element surface 210, may together define a second bifurcated fluid domain 206 for the second fluid 144 to flow through the plurality of path elements 200.

Referring to fig. 2C-2H, baffle units 250 include those unit cells of the three-dimensional lattice 104 having solid domains 252, the solid domains 252 including bifurcated path blinders 254, 256 integrally formed as part of the solid domains 252. The solid region 252 of the baffle unit 250 may include a first bifurcated path blind 254 and/or a second bifurcated path blind 256, the first bifurcated path blind 254 defining a boundary of the first bifurcated fluid region 204 and the second bifurcated path blind 256 defining a boundary of the second bifurcated fluid region 206. The solid region 252 of the baffle unit 250 may be entirely solid or may have a hollow space isolated from both the first bifurcated fluid region 204 and the second bifurcated fluid region 206. As discussed below with reference to fig. 3A-3C, the plurality of integrally formed continuous baffle units 250 including the first bifurcated path blind 254 together define a first bifurcated path baffle, and the plurality of integrally formed continuous baffle units 250 including the second bifurcated path blind 256 together define a second bifurcated path baffle.

The baffle unit 250 includes at least four peripheral planes. As shown, the baffle unit may include six perimeter planes. The six perimeter planes may be oriented orthogonal to X, Y or the Z-axis, respectively. The divergent path blinders 254, 256 define boundaries such that fluid in the divergent fluid domain does not flow through at least one peripheral plane of the baffle unit 250. The boundaries may be defined with respect to fluid flowing from the bifurcated fluid domains 204, 206 of the baffle unit 250 to successive unit cells of the three-dimensional lattice 104, or with respect to fluid flowing from the bifurcated fluid domains 204, 206 of successive unit cells to the baffle unit 250. The bifurcated path blind includes a portion of the solid domain 252 of the baffle unit 250 that defines such a boundary of the bifurcated fluid domains 204, 206 relative to the perimeter plane of the baffle unit 250. Even though the baffle unit 250 includes the bifurcated pathway blind 254, 256, in some embodiments, the baffle unit 250 may include one or more bifurcated fluid regions 204, 206 through which fluid may flow upward or across one or more perimeter planes of the unit cell through the one or more bifurcated fluid regions 204, 206. However, the presence of the bifurcation path blind 254, 256 in the unit cell distinguishes the unit cell as the baffle unit 250, as opposed to the path cell 200. The bifurcation path blinders 254, 256 may define the boundaries of the bifurcated fluid domains at one or more allowed planes, including a single perimeter plane of the baffle unit 250, all perimeter planes of the baffle unit 250, or a subset of perimeter planes of the baffle unit 250.

As shown in fig. 2C, 2E, 2F, 2H, the solid domain 252 of the baffle unit 250 may include a first bifurcated path blind 254 that defines a boundary of the first bifurcated fluid domain 204. As discussed below with reference to fig. 3A-3C, a plurality of integrally formed continuous baffle units including a first bifurcated path blind 254 together provide a first bifurcated path baffle. The first divergent path blind 254 may define the boundaries of each perimeter plane of the baffle unit 250 (fig. 2C and 2E) or the boundaries of a subset of perimeter planes of the baffle unit (fig. 2F and 2H). With the first diverging path blind 254 being continuous with another unit cell, such as the path cell 200, the fluid in the first diverging fluid region 204 may not flow through the perimeter plane of the baffle unit 250 having the first diverging path blind 254 because the first diverging path blind 254 defines the boundary of the first diverging fluid region 204.

The solid region 252 of the baffle unit 250 may include an exterior baffle unit surface 258, the exterior baffle unit surface 258 similar to the path unit 200, defining the second bifurcated fluid region 206. As shown, the second bifurcated fluid domain 206 of the baffle unit 250 includes paths that diverge in three directions (e.g., first and second perimeter planes with a second X-path 218 having an orthogonal orientation thereto, third and fourth perimeter planes with a second Y-path 220 having an orthogonal orientation thereto, and fifth and sixth perimeter planes with a second Z-path 222 having an orthogonal orientation thereto). The baffle unit 250 having the outer baffle unit surface 258 may be continuous with another baffle unit also having the outer baffle unit surface 258 and/or the path unit 200 having the outer path unit surface 208. A plurality of integrally formed continuous baffle units 250, each having an outer baffle unit surface 258, may together continuously define the second bifurcated fluid region 206 for the second fluid 144 to flow through the plurality of baffle units 250. Additionally or alternatively, the one or more baffle units 250 having the external baffle unit surface 258 contiguous with the one or more path units 200 having the external path unit surface 210 may together continuously define the second bifurcated fluid domain 206 for the second fluid 144 to flow through the one or more baffle units 250 and the path units 200.

As shown in fig. 2D, 2E, 2G, and 2H, the solid domain 252 of the baffle unit 250 may include a second bifurcated path blind 256 that defines a boundary of the second bifurcated fluid domain 206. Together, the plurality of integrally formed continuous baffle units 250 including the second bifurcation path blind 256 provide a second bifurcation path baffle, as discussed below with reference to fig. 3A-3C. The second bifurcation path blind 256 may define the boundaries of each perimeter plane of the baffle unit 250 (fig. 2D and 2E) or the boundaries of a subset of the perimeter planes of the baffle unit (fig. 2G and 2H). Additionally, the solid region 252 of the baffle unit 250 may include both a first bifurcated path blind 254 and a second bifurcated path blind 256 (fig. 2E and 2H), the first bifurcated path blind 254 and the second bifurcated path blind 256 defining boundaries of both the first bifurcated fluid region 204 and the second bifurcated fluid region 206, respectively (e.g., fig. 2A and 2B). With the second bifurcation path blind 256 being contiguous with another unit cell, such as the path cell 200, the fluid in the second bifurcation fluid domain 206 may not flow through the perimeter plane of the baffle unit 250 having the second bifurcation path blind 256 because the second bifurcation path blind 254 defines the boundary of the second bifurcation fluid domain 206.

The solid region 252 of the baffle unit 250 may include an interior baffle unit surface 260, the interior baffle unit surface 260 similar to the path unit 200, defining the first bifurcated fluid region 204. As shown, the first divergent fluid zone 204 of the baffle unit 250 includes paths that diverge in three directions (e.g., first X-paths 212 with first and second perimeter planes having orthogonal orientations thereto, first Y-paths 214 with third and fourth perimeter planes having orthogonal orientations thereto, and first Z-paths 216 with fifth and sixth perimeter planes having orthogonal orientations thereto). Baffle unit 250 having interior baffle unit surface 260 may be continuous with another baffle unit also having interior baffle unit surface 260 and/or path unit 200 having interior path unit surface 208. A plurality of integrally formed continuous baffle units 250, each having an interior baffle unit surface 260, may together continuously define the first bifurcated fluid domain 204 for the first fluid 138 to flow through the plurality of baffle units 250. Additionally or alternatively, one or more baffle units 250 having internal baffle unit surfaces 260 contiguous with one or more path units 200 having internal path unit surfaces 208 may together continuously define the first bifurcated fluid domain 204 for the first fluid 138 to flow through the one or more baffle units 250 and path units 200.

As shown in fig. 2E and 2H, the solid domain 252 of the baffle unit 250 may include both a first bifurcation path blind 254 and a second bifurcation path blind 256. The first bifurcated path blind 254 defines a boundary of the first bifurcated fluid region 204 and the second bifurcated path blind 256 defines a boundary of the second bifurcated fluid region 206. The first and second bifurcation path blinders 254 and 256 may each define the boundaries of each perimeter plane of the baffle unit 250 (fig. 2E), or the boundaries of a subset of the perimeter planes of the baffle unit (fig. 2H). As shown in fig. 2E, the solid domains 252 of the baffle unit 250 may occupy the entire baffle unit 250. Alternatively, as shown in fig. 2H, the solid region 252 of the baffle unit 250 may include an outer baffle unit surface 258 defining the second bifurcated fluid region 206, and an inner baffle unit surface 260 defining the first bifurcated fluid region 204.

Turning now to fig. 3A-3C, an exemplary three-dimensional lattice 104 of the heat exchanger 100 will be discussed in more detail. The exemplary heat exchanger 100 shown in fig. 3A-3C includes a three-dimensional lattice 104 of repeating unit cells. The three-dimensional lattice 104 is defined by a plurality of integrally formed, continuous unit cells. The unit cell includes a plurality of path cells 200 and a plurality of baffle cells 250, each conforming to a three-dimensional lattice. The plurality of path units 200 have a solid domain 202 comprising an interior path unit surface 208, the interior path unit surface 208 continuously defining a first diverging fluid domain 204 for the first fluid 138 to flow through the plurality of path units 200. The solid domains 202 of the plurality of path elements 200 additionally include exterior path element surfaces 210, the exterior path element surfaces 210 continuously defining second divergent fluid domains 206 for the second fluid 144 to flow through the plurality of path elements 200. The plurality of baffle units 250 are integrally formed among the plurality of path units 200. The plurality of baffle units 250 have a solid domain 252 that includes one or more first bifurcation path blinders 254 and/or one or more second bifurcation path blinders 256.

The example three-dimensional lattice 104 may include one or more first divergent path baffles 300 and/or one or more second divergent path baffles 302. The first divergent path baffle 300 may include a baffle unit 250 having one or more first divergent path blind plates 254 and/or one or more second divergent path blind plates 256. The second bifurcation path blind 302 may include a baffle unit 250 having one or more second bifurcation path blind 256 and/or one or more first bifurcation path blind 254. Together, the plurality of integrally formed continuous baffle units, each including a first bifurcated path blind 254, provide a first bifurcated path blind 300 within the three-dimensional lattice 104, the first bifurcated path blind 300 continuously defining boundaries of the first bifurcated fluid region 204. Together, the plurality of integrally formed continuous baffle units 250, each including a second bifurcated path blind 256, provide a second bifurcated path baffle 302 within the three-dimensional lattice 104, the second bifurcated path baffle 302 continuously defining boundaries of the second bifurcated fluid domain 206. The three-dimensional lattice can include one or more first bifurcated pathway baffles 300 that each continuously define boundaries of the first bifurcated fluid domain 204. Additionally or alternatively, the three-dimensional lattice may include one or more second bifurcated path baffles 302 that each continuously define boundaries of the second bifurcated fluid domain 206.

The first bifurcated pathway baffle 300 may include an exterior baffle unit surface 258 that is continuous with at least a portion of the exterior pathway unit surface 210 of the pathway unit 200. Such outer baffle unit surfaces 258 further continuously define the second bifurcated fluid region 206 and allow the second fluid 144 to flow through the plurality of baffle units 250 including the at least one first bifurcated path blind 254. The second bifurcated path baffle 302 may include an interior baffle unit surface 260 continuous with at least a portion of the interior path unit surface 208. Such internal baffle unit surfaces 260 further continuously define the first divergent fluid zone 204 and allow the first fluid 138 to flow through the plurality of baffle units 250 including at least one second divergent path baffle.

The internal path unit surfaces 208 of the plurality of path units 200 and the one or more first bifurcating path baffles 300 together define the first bifurcating serpentine flow channel 106 for the first fluid 138 to flow through the first bifurcating fluid domain 204. By way of example, but not limitation, the first bifurcated serpentine flow channel 106 may include a one-way configuration, a two-way configuration, a multi-way configuration, a split-flow configuration, a combined-flow configuration, and a spiral-flow configuration. The first bifurcating serpentine flow channel 106 may partially or completely overlap the second serpentine flow channel 108. The first bifurcated serpentine flow channel 106 may intersect the second bifurcated serpentine flow channel 108 one or more times. The first bifurcated serpentine flow channel 106 may pass through at least some of the baffle units 250 having second bifurcated path blinders 256. The second bifurcated serpentine flow channel 108 may pass through at least some of the baffle units 250 having the first bifurcated path blind plates 156.

The outer path cell surfaces 210 of the plurality of path cells 200 and the one or more second bifurcated path baffles 302 together define a second bifurcated serpentine flow channel 108 for the second fluid 144 to flow through the second bifurcated fluid region 206. Any flow orientation may be provided for the first serpentine flow channel 106 and the second serpentine flow channel 108. By way of example, but not limitation, the second bifurcated serpentine flow channel 108 may include a one-way configuration, a two-way configuration, a multi-way configuration, a split-flow configuration, a combined-flow configuration, and a spiral-flow configuration.

The first and second bifurcated serpentine flow channels 106, 108 may be oriented relative to each other in any desired configuration. By way of example, but not limitation, at least a portion of the first bifurcated serpentine flow channel 106 and at least a portion of the second bifurcated serpentine flow channel 108 may be constructed and arranged relative to one another using a parallel flow orientation, a reverse flow orientation, and/or a cross flow orientation. For the three-dimensional lattice 104 shown in fig. 3A-3C, the first and second bifurcated serpentine flow channels 106, 108 have a parallel flow orientation around at least a portion of the upper left region of the three-dimensional lattice 104, a reverse flow orientation around at least a portion of the bottom center region of the three-dimensional lattice 104, and a cross flow orientation around at least a portion of the right region of the three-dimensional lattice 104.

It will be appreciated that any desired configuration or arrangement may be utilized to selectively position the baffle units 250 throughout the three-dimensional lattice 104, thereby allowing the flow channels 106, 108 to have any desired configuration and arrangement. As such, the flow channels 106, 108 may be selectively constructed and arranged to provide improved heat transfer throughout the heat exchanger 100.

During operation of the heat exchanger 100, the first fluid 138 flows through the first bifurcated fluid domain 204 of the three-dimensional lattice 104 generally following the first serpentine flow channel 106, and the second fluid 144 flows through the second bifurcated fluid domain 206 of the three-dimensional lattice 104 generally following the second serpentine flow channel 108. The first fluid 138 may be a relatively hotter fluid and the second fluid 144 may be a relatively cooler fluid, or vice versa. Heat may be transferred between the first fluid and the second fluid through the solid domains 202, 252, the solid domains 202, 252 separating the first fluid domain 204 from the second fluid domain 206.

The first fluid 138 flows from the first fluid inlet plenum 114 to the first fluid inlet region 116 of the first bifurcated fluid region 204 through the first bifurcated serpentine flow channel 106 and out to the first fluid outlet plenum 118 through the outlet region 120 of the first bifurcated fluid region 204. The second fluid 144 flows from the second fluid inlet plenum 126 to the second fluid inlet region 128 of the second bifurcated fluid region 206 through the second bifurcated serpentine flow channel 108 and out to the second fluid outlet plenum 130 through the outlet region 132 of the second bifurcated fluid region 206.

In some embodiments, the fluid entering the three-dimensional lattice structure may exhibit significant pressure loss. Typically, the shear stress is highest at the entrance of the corresponding unit cell of the three-dimensional lattice 104, where the boundary layer thickness is smallest. The boundary layer thickens with decreasing shear stress and the fluid may exhibit fully developed flow characteristics. The pressure loss can be described by a resistance coefficient K, which corresponds to the inlet geometry of the unit cell at the interface between the respective fluid inlet plenum and the inlet region of the respective fluid domain. Several methods for determining the drag coefficient K are known in the art. As an example, the drag coefficient K may be calculated as:where f is the coefficient of friction, L is the equivalent length of the inlet of the unit cell, and D is the internal diameter or cross-section of the unit cell. A larger drag coefficient corresponds to a larger pressure loss across the inlet of the unit cell. In some embodiments, the drag coefficient K can be minimized or reduced by reducing the equivalent length L of the unit cell inlet. A lower coefficient of resistance K corresponds to a smaller pressure loss across the inlet of the unit cell.

Exemplary values of the drag coefficient K for various unit cell inlet geometries are provided in fig. 4. A unit cell with a flush or square edge inlet facing the inlet plenum may have a drag coefficient K of about 0.5, for example between 0.4 and 0.6 or between 0.45 and 0.55. A unit cell having an outwardly projecting inlet facing the inlet plenum may have a drag coefficient K of about 0.78, for example between 0.7 and 0.85 or between 0.75 and 0.8. In contrast, a unit cell with a circular unit cell inlet facing the inlet plenum may have a lower drag coefficient K, which may be calculated as: where f is the coefficient of friction, r is the radius of the circular unit cell inlet, and D is the inside diameter or cross-section of the unit cell. The unit cells with circular unit cell inlets may have a drag coefficient K ranging from 0.02 to 0.4, such as from 0.04 to 0.35, such as from 0.02 and 0.09, such as from 0.04 and 0.15, such as from 0.09 and 0.24, such as from 0.15 and 0.28, such as from 0.24 and 0.3. The resistance coefficient K of a unit cell with a circular unit cell inlet may be in the range from more than 0.02 to less than 0.4, such as below 0.3, such as below 0.28, such as below 0.24, such as below 0.15, such as below 0.09, such as below 0.04.

As shown in fig. 2A and 2B, the path cell 200 includes a solid domain 202, and when the solid domain 202 is positioned adjacent to the first fluid inlet plenum 114, the solid domain 202 may provide a flush or square-edged inlet to a first fluid domain 204 facing the first fluid inlet plenum 114. In some embodiments, the solid domain 202 of the routing unit shown in fig. 2A and 2B may provide an outwardly protruding inlet to the first fluid domain 204. On the other hand, the solid domain 202 of the path cell 200 shown in fig. 2A and 2B includes an outer path cell surface 210, and when the outer path cell surface 210 is positioned adjacent to the second fluid inlet plenum 126, the outer path cell surface 210 can provide a circular unit cell inlet to the second fluid domain 206. Such a circular unit cell inlet to the second fluid region 206 advantageously exhibits a minimal or reduced drag coefficient K. However, a square edge or outwardly protruding inlet to the first fluid domain may exhibit a higher coefficient of resistance K relative to the inlet to the second fluid domain.

However, in some embodiments, the three-dimensional lattice 104 of repeating unit cells may include circular unit cell inlets to both the first and second fluid domains. This may be accomplished, for example, by including a plurality of partial unit cells 304 among a plurality of integrally formed continuous unit cells that define the three-dimensional lattice 104. The plurality of partial unit cells 304 are similarly integrally formed and continuous and similarly define respective portions of the three-dimensional lattice 104 of repeating unit cells. Such a partial unit cell 304 introduces a partial phase shift to the three-dimensional lattice 104 of repeating unit cells. The magnitude of the phase shift corresponds to the ratio of a portion of the unit cells 304 to the entire unit cells. The fractional unit cells 304 may introduce a fractional phase shift in a phase ranging from 1/16 to 15/16, such as a phase from 1/8 to 7/8, such as a phase from 1/4 to 3/4, such as a phase from 3/8 to 5/8. In the exemplary embodiment, the partial phase shift is a phase of 1/2.

The partial unit cells 304 may be provided at any desired location of the three-dimensional lattice 104, including at the first fluid inlet region 116 (e.g., adjacent to the first fluid inlet plenum 114), at the second fluid inlet region 128 (e.g., adjacent to the second fluid inlet plenum 126), and/or at an intermediate region of the three-dimensional lattice 104. The partial unit cell may be a partial path cell 200 and/or a partial barrier cell 250. For example, the partial baffle unit 250 may include a first diverging path blind 254 and/or a second diverging path blind 256.

As shown in fig. 3A-3C, in one embodiment, a plurality of partial path units 304 are provided at the first fluid inlet region 116, which may be adjacent to the first fluid inlet plenum 114 (fig. 1). As such, the three-dimensional lattice 104 of repeating unit cells includes a first circular unit cell inlet 306 to the first fluid domain 204. The partial path unit 304 and the corresponding first circular unit cell inlet 306 to the first fluid domain 204 are more clearly depicted in fig. 5A-5C. As shown, the first fluid 138 follows the circular flow channel 500 defined by the inner path unit surface 208 of the partial path unit 304. The three-dimensional lattice 104 also includes a second circular unit cell inlet 308 to the second fluid domain 206. A second circular unit cell inlet 308 to a second fluid domain 206 corresponding to the outer path cell surface 210 of the path cell 200 is more depicted in fig. 6A-6C. As shown, the second fluid 144 follows a circular flow channel 600 defined by the interior path cell surface 208 of the path cell 200. In another embodiment, all or a portion of the three-dimensional lattice 104 of repeating unit cells may be shifted in phase by a fraction, and a plurality of partial unit cells 304 may be provided adjacent the second fluid inlet plenum 126 (fig. 1), similarly provided to a first circular unit cell inlet 306 to the first fluid domain 204 and a second circular unit cell inlet 308 to the second fluid domain 206.

Any desired technique may be used to fabricate various aspects of the heat exchanger 100, including the three-dimensional lattice 104 and its corresponding unit cells, as well as the various other components described herein. Techniques that may be used to manufacture such various components include additive manufacturing, machining, drilling, casting, or combinations thereof or any other technique. Additive manufacturing processes may include any process involving layer-by-layer construction or additive manufacturing (as opposed to material removal in conventional machining processes). This process may also be referred to as a "rapid manufacturing process". Additive manufacturing processes include, but are not limited to: direct Metal Laser Melting (DMLM), laser mesh fabrication (LNSM), electron beam sintering, Selective Laser Sintering (SLS), 3D printing, for example by inkjet and laser printing, Binder Jetting (BJ), Material Jetting (MJ), Photopolymer Jetting (PJ), Stereolithography (SLA), Electron Beam Melting (EBM), Fused Deposition Modeling (FDM), laser engineered mesh formation (LENS), Direct Metal Deposition (DMD), and Hybrid Processing (HP).

Any desired materials may be used to fabricate the various aspects of the heat exchanger 100, including the three-dimensional lattice 104 and its corresponding unit cells, as well as the various other components described herein. Materials that may be used to fabricate such various components include aluminum alloys, steel alloys, titanium alloys, nickel alloys (e.g., superalloys), and composites such as Ceramic Matrix Composite (CMC) materials. Exemplary CMC materials may include silicon carbide, silicon, silica, or alumina matrix materials, and combinations thereof. Ceramic fibers may be embedded within the matrix, such as oxidation stable reinforcing fibers including monofilaments similar to sapphire and silicon carbide, yarns including silicon carbide, aluminum silicate, chopped whiskers and fibers, and optionally ceramic particles (e.g., oxides of Si, Al, Zr, Y, and combinations thereof) and inorganic fillers (e.g., pyrophyllite, wollastonite, mica, talc, kyanite, and montmorillonite). As a further example, the CMC material may also include silicon carbide (SiC) or carbon fiber cloth. In some embodiments, the material forming the three-dimensional lattice 104 may be a material suitable for facilitating heat transfer, such as a thermally conductive material.

This written description uses exemplary embodiments to describe the presently disclosed subject matter, including the best mode, and also to enable any person skilled in the art to practice such subject matter, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the presently disclosed subject matter is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.