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Method for producing components with internal architectures, such as micro-channel reactors, via diffusion bonding sheets

United States Patent

March 8, 2011
View the Complete Patent at the US Patent & Trademark Office
National Energy Technology Laboratory - Visit the Technology Transfer Website
Producing microchannels using graduated diffusion bonding of a stack of precision machined foils or sheets (laminates) to make a micro-channel reactor
This invention relates to a method for producing components with internal architectures, and more particularly, this invention relates to a method for producing structures with microchannels via the use of diffusion bonding of stacked laminates. Specifically, the method involves weakly bonding a stack of laminates forming internal voids and channels with a first generally low uniaxial pressure and first temperature such that bonding at least between the asperites of opposing laminates occurs and pores are isolated in interfacial contact areas, followed by a second generally higher isostatic pressure and second temperature for final bonding. The method thereby allows fabrication of micro-channel devices such as heat exchangers, recuperators, heat-pumps, chemical separators, chemical reactors, fuel processing units, and combustors without limitation on the fin aspect ratio.
Alman; David E. (Corvallis, OR), Wilson; Rick D. (Corvallis, OR), Davis; Daniel L. (Albany, OR)
The United States of America as represented by the United States Department of Energy (Washington, DC), N/A (
12/ 394,084
February 27, 2009
GOVERNMENT INTERESTS The United States Government has rights in this invention pursuant to the employer-employee relationship of the Government to the inventors as U.S. Department of Energy employees and site-support contractors at the National Energy Technology Laboratory.