The present disclosure concerns a method for embossing a component, a method for connecting a component to a second component via a substance-to-substance bond, and a device, e.g., a heat exchanger, having such a component. The method for embossing includes embossing a support groove into the component at least in some sections at a first surface portion of the component; embossing a functional groove into the component at the first surface portion; wherein the functional groove is arranged spaced apart from the support groove at least in some sections; and wherein the functional groove is formed for partially receiving a second component for a substance-to-substance bond.

A method of building a heat exchanger includes forming the heat exchanger with layer-by-layer additive manufacturing. A first hollow annulus is formed. A body of the heat exchanger is formed to be integrally connected to and grown upwards from the first hollow annulus. The body includes an exterior wall and a heat exchanger core disposed within the exterior wall. The body defines an interior that is cylindrically shaped with an axis oriented parallel to a direction of gravity. The first annulus is disposed on a gravitational bottom of the body. A second hollow annulus is formed integrally connected to and grown upwards from a gravitational top of the body. Residual powder is removed from a bottom of the heat exchanger.

A method for forming a hybrid heat exchanger is provided. The method includes laser-texturing a metal surface to create a plurality of microstructures and subsequently melt-bonding a plastic component to the plurality of microstructures. During melt-bonding, plastic material penetrates the plurality of microstructures and conforms to the plastic component to the metal surface. After hardening inside the microstructures, the plastic component adheres to the metal surface as a hybrid component. As a result, a fastener or snap connection is not required, and the plastic-metal joint provides a barrier to water, glycol-based fluids, air, and other fluids.

A method for additively manufacturing a microstructure from a caloric material includes providing a geometry of the microstructure to a processor of an additive manufacturing device, the geometry defining a plurality of microfeatures of the microstructure. The method also includes generating, via the processor, a three-dimensional (3D) model representative of the geometry of the microstructure, wherein one or more of the plurality of microfeatures are represented in the 3D model by a non-arcuate profile. Further, the method includes printing, via the additive manufacturing device, the microstructure from the caloric material according to the 3D model. As such, the non-arcuate profile reduces a file size of the 3D model as compared to an arcuate profile.

Disclosed herein is a thermal interface material comprising a sheet extending between a first major surface and a second major surface, the sheet comprising a base material; and a filler material embedded in the base material comprising anisotropically oriented thermally conductive elements; wherein the thermally conductive elements are preferentially oriented along a primary direction from the first major surface towards the second major surface to promote thermal conduction though the sheet along the primary direction; and wherein the base material is substantially free of silicone.

Drawn polymer fibers have internal channels running, at least partially, through the length of the fibers. These fibers may be configured to for use as thermal isolators that can thermally isolate material at the central core of the fiber from the outside environment. In such instances, the channels may be used as insulating channels and/or a heating or cooling fluid can be pumped through the channels to maintain the temperature of the material at the inner core. As another application, the fibers may be used as recuperative, regenerative, parallel-flow, counter-flow, cross-flow or condenser/evaporator heat exchangers. In this case, the channels may be used to direct fluid flow. The fiber may allow for the exchange of heat between fluids in the channels.

Method for providing a heat exchanger block (B) with a housing (H), said heat exchanger block (B) comprising at least a first outer surface region (B1) and a second outer surface region (B2) opposite said first outer surface region (B1), said housing (H) comprising at least a first housing portion (W1) covering/engaging said first outer surface region (B1) of said heat exchanger block (B) and a second housing portion (W2) opposite said first housing portion (W1) and covering/engaging said second outer surface region (B2) of said heat exchanger block (B), said method comprising at least the following steps: a) moulding said first housing portion (W1) to said first outer surface region (B1); and b) moulding said second housing portion (W2) to said second outer surface region (B2).

A device, e.g., a heat exchanger, is disclosed. The device includes a first component and a second component. The first component has at least a first surface portion and a second surface portion. The first surface portion and the second surface portion are located opposite to one another and are spaced apart from one another. The first component includes a first support groove provided at the first surface portion and a functional groove provided at the first surface portion. The functional groove is arranged spaced apart from the first support groove at least in some sections. The functional groove is structured and arranged for partially receiving a second component for a substance-to-substance bond.

The present invention relates to a method for manufacturing a 3D item (100) by means of fused deposition modelling (FDM), the method comprising the steps of: a) providing a shell component (5) comprising a thermoplastic 3D printable shell material having a shell melting temperature (Tms) and/or a shell glass transition temperature (Tgs); b) providing a core component (2) comprising a plurality of thermally conductive wires (3) and a flexible mantle (4) enclosing the plurality of thermally conductive wires (3); c) feeding the shell component (5) into a nozzle (6) of a 3D printer, the nozzle (6) having a nozzle temperature (Tn) being equal to or greater than the shell melting temperature (Tms) and/or the shell glass transition temperature (Tgs); d) a layer-wise depositing of the 3D printable shell material and the core component (2) to provide the 3D item (100) comprising a core-shell layer (100) of 3D printed material, wherein the 3D printed material comprises a core (102) comprising the core component, and shell (105) comprising 3D printed shell material, wherein the shell (105) at least partly encloses the core (102).

A method for manufacturing an arrangement for the transport of media includes a base body formed as a blow-molded part and at least one functional element, in which a preform consisting of polymeric material and at least one functional element are provided and arranged in a blow mold, wherein the base body is formed from the preform, wherein the preform bears against the functional element during forming, wherein the blow mold has a first mold element and a second mold element, wherein the base body is formed from the preform between the first mold element and the second mold element, wherein the first mold element and the second mold element bear against the functional element in such a way that excess material produced from the preform in the area of the functional element during blow molding can be removed.