Three-dimensional film structures and methods

• US 6,221,463 B1
• Filed: 07/08/1998
• Issued: 04/24/2001
• Est. Priority Date: 07/08/1998
• Status: Expired due to Fees

• Current Assignee: Eugene W. White
• Original Assignee: Eugene W. White
• Inventors: White, Eugene W.
• Primary Examiner(s): LONEY, DONALD J
• Application Number:
  US09/112,034
• Time in Patent Office: 1,021 Days
• Field of Search: 428/174, 428/178, 156/196, 156/199, 156/228, 210/660, 261/118, 261/112.1, 261/DIG.72, 165/60, 165/158, 165/900, 553/42, 553/44, 554/40, 555/21
• US Class Current: 428/174
• CPC Class Codes: B01D 53/885 Devices in general for catalytic purification of waste gases
• CPC Class Codes: B32B 2323/04 Polyethylene
• CPC Class Codes: B32B 2367/00 Polyesters, e.g. PET, i.e. polyethylene terephthalate
• CPC Class Codes: B32B 2369/00 Polycarbonates
• CPC Class Codes: B32B 2605/08 Cars
• CPC Class Codes: B32B 2605/18 Aircraft blades, propellers B32B2603/00
• CPC Class Codes: B32B 3/26 characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids foam layer B32B5/18; layer of synthetic resin characterised by fillers that create voids or cavities B32B27/205; characterised by an apertured layer
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: F28D 9/0037 the conduits for the other heat-exchange medium also being formed by paired plates touching each other F28D9/0043 takes precedence
• CPC Class Codes: F28F 21/065 the heat-exchange apparatus employing plate-like or laminated conduits
• CPC Class Codes: F28F 3/04 the means being integral with the element
• CPC Class Codes: Y10S 261/72 Packing elements
• CPC Class Codes: Y10T 428/24628 Nonplanar uniform thickness material

Abstract

A new fundamental structure that is simply and inexpensively formed offers a wide variety of functional attributes. The structure is formed from thin film sheet stock by pressure induced formation of select arrays of depressions and raised portions. The patterns formed provide an approximate minimal surface. Composite structures created by selective arrangement of the deformed sheets provide a highly functional arrangement of passageways and support lattice. These structures have low density, high strength, and select fluid carrying and heat exchange capabilities.

Claims

1. A heat exchanger comprising plural thin films, each film having an array of regularly spaced raised portions and depressions forming a uniform matrix of deformations, said films arranged in layers attached at selective junctions defined by said depressions and raised portions aligned in adjacent arrangement, wherein corresponding adjacent depressions and raised portions are selectively machined to allow interconnection between adjacent layers, and manifold sheet placed on a surface orthogonal to said layers with selective openings to control ingress and egress of thermal fluids.

2. The heat exchanger of claim 1 wherein the plural thin films are formed of a thermoplastic material.

3. The heat exchanger of claim 1 wherein the thermal fluids include air and water.

4. The heat exchanger of claim 1 wherein the matrix of deformations form an approximate periodic minimal surface.

5. A heat exchanger comprising:

a plurality of film structures each including a uniform array of raised elevations and depressions spaced at regular intervals to form a matrix, said film structures arranged in layers and securely attached at corresponding raised portions and depressions aligned in adjoining arrangement, said attached corresponding raised portions and depressions providing interconnection between layers for fluid flow; and

at least two manifolds placed on a surface orthogonal to said layers, said manifolds having apertures to control ingress and egress of fluids.

6. The heat exchanger according to claim 5, wherein said film structures are made of a thermoplastic material.

7. The heat exchanger according to claim 5, wherein said fluids include air and water.

8. A heat exchanger having a low density, high strength to weight ratio comprising:

a plurality of individually formed three dimensional structures having a series of raised portions and depressions defining a minimal surface area therebetween, said structures layered and attached at selected and corresponding raised portions and depressions and providing a high strength to weight ratio, said structures machined at said selected and corresponding raised portions and depressions creating a network of chambers throughout said exchanger; and

at least two manifolds placed on surfaces orthogonal to said structures, said manifolds having apertures to control ingress and egress of thermal fluids in the network of chambers.

9. An ion exchanger comprising:

a plurality of individually formed three dimensional porous structures having a series of raised portions and depressions defining a minimal surface area therebetween, said structures layered and attached at selected and corresponding raised portions and depressions to form segregated passages within said ion exchanger, said structures machined at said selected and corresponding raised portions and depressions creating a network of chambers throughout said exchanger for passage of fluids therein;

at least two manifolds placed on surfaces orthogonal to said structures, said manifolds having apertures to control ingress and egress of fluids in the network of chambers.