Annular heat exchanger

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Solution Overview

Problem

Conventional heat exchangers in aerospace applications are bulky and heavy due to the need for numerous pneumatic ducts and couplings, which increase volume and weight, and do not efficiently integrate with other components, leading to pressure losses and complex assembly processes.

Innovation Solution

An annular heat exchanger with a monolithic core and header configuration, utilizing additive manufacturing to create contoured hexagonal flow channels that interleave hot and cold fluid paths, allowing direct integration with cylindrical components and reducing the need for external ducts and couplings, thereby minimizing weight and volume while enhancing heat transfer efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional heat exchangers use numerous pneumatic ducts and couplings to deliver and distribute fluid flows, then heat exchange function is achieved, but system volume and weight increase

Engineering Contradiction:

Improveheat exchange functionVSAvoidsystem weight

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

The patent merges the heat exchanger core with the header into a single integrated component. The header is formed as an integral part of the core structure, eliminating the need for separate ducts and couplings to connect fluid sources to the heat exchange channels. This consolidation directly reduces system weight while maintaining heat exchange functionality.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated header-core structure serves multiple functions simultaneously: it acts as both the fluid distribution system (header) and the heat exchange surface (core). This multi-functionality eliminates the need for separate pneumatic ducting systems, reducing overall system weight and complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If conventional heat exchangers use numerous pneumatic ducts and couplings, then fluid flow distribution is achieved, but system volume increases

Engineering Contradiction:

Improvefluid flow distributionVSAvoidsystem volume

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

The patent combines the header and core into a single integrated structure where fluid distribution channels are formed directly within the core assembly. This eliminates the volume occupied by external pneumatic ducts and couplings while maintaining effective fluid flow distribution to all heat exchange channels.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The fluid distribution channels are nested within the core structure itself, with the header forming an integral part of the core's internal architecture. This nesting approach allows fluid distribution functionality to be embedded within the heat exchange volume rather than requiring additional external space.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Ease of manufacture

If conventional heat exchangers use separate header and core components, then assembly flexibility is achieved, but assembly process becomes complex

Engineering Contradiction:

Improveassembly flexibilityVSAvoidassembly process complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent merges the header and core into a single monolithic component manufactured using additive manufacturing technology. This eliminates the need for complex assembly processes involving multiple separate parts, fasteners, and sealing elements, while the additive manufacturing process itself provides manufacturing flexibility for complex geometries.

Inventive Principle:

Principle #5Merging (Combining)

4Reliability

If conventional heat exchangers use traditional configurations, then heat exchange is achieved, but pressure losses increase

Engineering Contradiction:

Improveheat exchange efficiencyVSAvoidpressure losses

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent implements locally optimized flow channels within the integrated header-core structure. The additive manufacturing process enables tailored channel geometries that optimize fluid flow distribution and minimize pressure losses at specific locations, while maintaining effective heat exchange across the entire core surface.

Inventive Principle:

Principle #3Local quality

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The annular heat exchanger design reduces system weight and volume, minimizes pressure losses, and integrates seamlessly with other components, improving heat transfer efficiency and assembly efficiency compared to traditional configurations.

Implementation Method 1

heat exchangers provide a highly effective means of exchanging heat from a hot fluid to a cold fluid

Methodology Applied

Scientific EffectHeat transfer: Heat Exchanger

Data Source

PatentUS11802736B2Annular heat exchanger

Publication Date: 2023.10.31 HAMILTON SUNDSTRAND CORP

AI summary

A heat exchanger includes a header and an annular core fluidly connected to the header. The annular core includes an inner diameter, an outer diameter, first flow channels arranged in a first set of layers, and second flow channels arranged in a second set of layers and interleaved with the first flow channels. Each of the first flow channels includes a first inlet, a first outlet, and a first axial region extending between the first inlet and the first outlet. Each of the second flow channels includes a second inlet, a second outlet, and a second axial region extending between the second inlet and the second outlet.