Branched Heat Exchanger Core With Parallel Flow Interconnections
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional heat exchangers in aircraft environmental control systems suffer from high pressure drops and poor flow distribution, leading to reduced thermal energy transfer efficiency due to their design limitations in non-layer-by-layer additive manufacturing processes.
Innovation Solution
A heat exchanger core is designed using topology optimization and constructed via layer-by-layer additive manufacturing, featuring an array of branched channels with varying shapes and configurations that minimize pressure drop and maximize thermal energy transfer, while allowing for continuous transitions and reduced mass.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional heat exchanger designs are used with non-layer-by-layer additive manufacturing processes, then manufacturing simplicity is maintained, but pressure drop increases and flow distribution becomes poor
Solution Approach 1:
The patent changes the manufacturing process parameter from conventional non-layer-by-layer additive manufacturing to layer-by-layer additive manufacturing. This enables the creation of complex branched channel geometries with optimized flow paths, resulting in improved flow distribution and reduced pressure drop while maintaining manufacturing capability through advanced additive processes.
Solution Approach 2:
The heat exchanger core is segmented into multiple branched channels with systematic splits and junctures. The array includes a first split at the inlet header, a first juncture at the outlet header, multiple secondary splits, and multiple secondary junctures. This segmentation creates parallel flow paths that improve flow distribution across the core.
2Device complexity
If conventional heat exchanger designs are used, then design simplicity is maintained, but thermal energy transfer efficiency decreases
Solution Approach 1:
The topology optimization tool modifies design parameters including channel geometry, split positions, and juncture configurations to maximize thermal energy transfer. The layer-by-layer additive manufacturing process enables realization of these optimized parameters, creating a design that improves thermal efficiency despite increased complexity.
Solution Approach 2:
The patent transitions from two-dimensional conventional heat exchanger designs to three-dimensional branched channel structures. The array includes multiple levels of splits and junctures creating complex 3D flow paths, which increase the effective heat transfer surface area and improve thermal energy transfer efficiency.
3Device complexity
If conventional heat exchanger designs are used, then structural simplicity is maintained, but mass reduction opportunities are lost
Solution Approach 1:
The topology optimization process modifies structural parameters to minimize mass while meeting performance requirements. The layer-by-layer additive manufacturing process enables fabrication of these optimized structures with reduced material usage, achieving mass reduction through precise control of channel walls and support features.
Solution Approach 2:
The optimization process extracts only the necessary material required for functional performance. By removing redundant material and creating optimized channel geometries with variable wall thicknesses, the design achieves minimum mass while maintaining structural integrity and thermal performance.
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 solution reduces pressure drop and enhances thermal energy transfer efficiency by optimizing the heat exchanger core's design and construction, resulting in improved performance and structural reliability.
Implementation Method 1
heat exchangers are utilized to exchange thermal energy from one fluid stream to another fluid stream
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A heat exchanger (10) includes an external casing (12) and a core (22). The external casing (12) includes a first inlet (14), a first outlet (16), a second inlet (18), and a second outlet (20). The core (22) includes an array (28) of branched channels (30) connecting the first inlet (14) and first outlet (16), an inlet header (24), and an outlet header (26). The inlet header (24) is integrally formed with and fluidly connected to the first inlet (14). The outlet header (26) is integrally formed with and fluidly connected to the first outlet (16). The branched channels and the external casing (12) define a fluidic passage. The array (28) ofbranched channels (30) includes a first split (34), a first juncture (36), a secondary split (234), a secondary juncture (236), and a subset of splits and junctures. The first split (34) and first juncture (36) are common to an entirety of the array (28) of branched channels (30). The subset of splits and junctures route fluid through interconnections (130) between fluidly parallel branched channels.