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US 11,091,848 B2Granted
Component with differing material properties
AssigneeUnison Industries, LLC
InventorsGordan Tajiri, Donald Templeton, Dattu G V Jonnalagadda, Yanzhe Yang
Life of this patent
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Abstract
A component can be formed having an integral monolithic body. The integral monolithic body can be formed utilizing electroforming processes such as electrodeposition of metal alloys. The electroformed monolithic body can be formed utilizing multiple anodes powered by multiple power sources. The monolithic body can have differing local material properties determined during formation of the component.
Claims20
A method of forming a heat exchanger, the method comprising:
- coupling a base plate and a manifold section to a sacrificial mold having an outer surface defining a cathode, the sacrificial mold including a set of return manifolds, at least one manifold connection, and a set of fluid passage channel structures;
- providing at least two anodes;
- forming, with a controller connected to the at least two anodes, a monolithic component by way of electroforming over the outer surface of the sacrificial mold and the base plate utilizing a single metal constituent solution, and wherein the monolithic component includes at least two discrete zones, complementary to the at least two anodes, with each discrete zone of the at least two discrete zones having differing local material properties within a single layer, the discrete zones having the differing local material properties realized by controlling a local concentration or a crystalline formation during the electroforming of the single layer via the controller connected to the at least two anodes;
- and
- removing the sacrificial mold to define the heat exchanger having the monolithic component with a set of fluid passages at least some of which are fluidly coupled via the set of return manifolds.
2 more elements
A method of forming a heat exchanger, the method comprising:
- attaching at least one sacrificial mold having an outer surface to a base plate, wherein the at least one sacrificial mold includes a set of return manifolds, at least one manifold connection, and a set of fluid passage channel structures;
- electroforming a single metallic layer over exposed outer surfaces of the base plate and the outer surface of the sacrificial mold with a set of anodes including at least two anodes, wherein the electroforming includes controlling an amount of a first specified metal or a crystalline formation in a first zone of the single metallic layer with a first anode of the set of anodes to form a first portion of the heat exchanger, and controlling an amount of a second specified metal or a crystalline formation in a second zone of the single metallic layer with a second anode of the set of anodes to form a second portion of the heat exchanger, the first zone being discrete from the second zone and the first zone and the second zone having differing material properties;
- and
- removing the at least one sacrificial mold to define the heat exchanger having a unitary component including the first portion and the second portion and a set of fluid passages at least some of which are fluidly coupled via the set of return manifolds.
1 more element
Dependencies are inferred from the claim text.