Heat exchanger riblet and turbulator features for improved manufacturability and performance

A method of additively manufacturing a heat exchanger comprising a plurality of first layers for receiving a first fluid, each of the plurality of first layers including one or more first layer flow channels, and a plurality of second layers for receiving a second fluid, each of the plurality of second layers including one or more second layer flow channels, the method comprising the steps of:

• (a) additively manufacturing one of the plurality of first layers comprising one or more first layer flow channels defining a first fluid flow direction and having one or more first features and one or more third features opposite the first features, wherein each first feature comprises a riblet comprising a riblet peak and a riblet valley, and each third feature comprises a riblet comprising a riblet peak and riblet valley, wherein, with respect to each of the first and third features:
• the riblet peak and riblet valley defines a riblet slope;
• the riblet peak and riblet valley defines a riblet axis;
• the riblet axis is generally parallel to the first fluid flow direction;
• and
• the riblet valley of the first feature is aligned with and opposite the riblet valley of the third feature in a direction generally perpendicular to the riblet axis;
• (b) additively manufacturing one of the plurality of second layers comprising one or more second layer flow channels defining a second fluid flow direction substantially perpendicular to the first fluid flow direction and having one or more second features, wherein each second feature comprises a turbulator, comprising a turbulator peak and a turbulator valley;
• wherein:
• the turbulator peak and turbulator valley defines a turbulator slope;
• the turbulator peak and turbulator valley defines a turbulator axis, and
• the turbulator axis is generally perpendicular to the second fluid flow direction;
• and
• (c) alternately repeating steps (a) and (b) until a desired number of first and second layers is obtained;
• wherein:
• a layer wall is disposed between each adjacent first layer and second layer, fluidly separating the corresponding first layer flow channels from the corresponding second layer flow channels.

A heat exchanger comprising:

• a plurality of first layers for receiving a first fluid, each of the plurality of first layers including one or more first layer flow channels defining a first fluid flow direction, at least one of the one or more first layer flow channels having one or more first features and one or more third features opposite the first features, wherein each first feature comprises a riblet comprising a riblet peak and a riblet valley, and each third feature comprises a riblet comprising a riblet peak and a riblet valley, wherein, with respect to each of the first and third features:
• the riblet peak and riblet valley defines a riblet slope;
• the riblet peak and riblet valley defines a riblet axis;
• the riblet axis is generally parallel to the first fluid flow direction;
• and
• the riblet valley of the first feature is aligned with and opposite the riblet valley of the third feature in a direction generally perpendicular to the riblet axis;
• and
• a plurality of second layers for receiving a second fluid;
• each of the plurality of second layers including one or more second layer flow channels defining a second fluid flow direction that is substantially perpendicular to the first fluid flow direction, at least one of the one or more second layer flow channels having one or more second features and one or more fourth features opposite the second features, wherein each second feature comprises a turbulator comprising a turbulator peak and a turbulator valley, and each fourth feature comprises a turbulator comprising a turbulator peak and a turbulator valley;
• wherein, with respect to each of the second and fourth features:
• the turbulator peak and turbulator valley defines a turbulator slope;
• the turbulator peak and turbulator valley defines a turbulator axis;
• the turbulator axis is generally perpendicular to the second fluid flow direction;
• and
• the turbulator peak of the second feature is aligned with and opposite the turbulator peak of the fourth feature in a direction generally perpendicular to the turbulator axis;
• wherein:
• each of the plurality of first layers is sandwiched between adjacent second layers;
• each of the plurality of second layers is sandwiched between adjacent first layers;
• and
• a layer wall is disposed between each adjacent first layer and second layer, fluidly separating the corresponding first layer flow channels from the corresponding second layer flow channels.