Method of making microchanneled heat exchangers utilizing sacrificial

Abstract

A method of making a unitary channeled heat exchanger wherein the unitary heat exchanger is to be connected with a first fluid circulation system. The unitary heat exchanger preferably includes a first manifold connectible to the first fluid circulation system and a heat transfer body fluidically connected to the manifold. The unitary heat exchanger is fabricated by forming a sacrificial core with a first manifold forming portion and a body forming portion having surfaces shaped generally similar to the desired shapes of the first manifold and body of the unitary heat exchanger, depositing heat exchanger forming material about the sacrificial core to form a shell about the sacrificial core, the shell preferably including a manifold and a body integrally formed, providing an access opening through the shell of the unitary heat exchanger, and removing the sacrificial core from within the shell of the unitary heat exchanger through the access opening, thereby leaving passages within the manifold and the body of the unitary heat exchanger that are in fluidic communication with one another. The body forming portion of the sacrificial is further preferably made with one or more holes so that upon deposition of heat exchanger forming material, posts are formed connecting upper and lower plates of the shell of the heat exchanger for increased structural integrity. Additionally, the deposition can be advantageously controlled so that apertures remain after the post or posts are formed, which may be used for mounting components or as part of a second fluid circulation circuit.