Branched Heat Exchanger Core for Low Pressure Drop
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Solution Overview
Problem
Conventional heat exchangers in aircraft environmental control systems suffer from high pressure drops and poor flow distribution, leading to reduced efficiency in thermal energy transfer due to their design limitations in non-layer-by-layer additive manufacturing processes.
Innovation Solution
A heat exchanger design utilizing topology optimization and layer-by-layer additive manufacturing to create a core with an array of branched channels, splits, and junctures that minimizes pressure drop, maximizes thermal energy transfer, and reduces mass, featuring a hybrid cross-counter flow behavior and continuous, homogeneous transitions between components.
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 heat exchanger core is divided into multiple fluidly parallel branched channels with splits and junctures, creating a segmented flow distribution network that improves flow uniformity across the core while maintaining manufacturability through additive manufacturing
Solution Approach 2:
The patent transitions from conventional two-dimensional heat exchanger designs to three-dimensional branched channel networks with multiple levels of splits and junctures, enabling superior flow distribution and thermal performance through complex spatial configurations achievable only through additive manufacturing
2Device complexity
If conventional heat exchanger designs are used, then design simplicity is maintained, but thermal energy transfer efficiency decreases
Solution Approach 1:
The heat exchanger features non-uniform distribution of branched channels with varying densities and configurations in different regions, optimizing thermal energy transfer efficiency by matching channel distribution to local thermal requirements while maintaining overall design coherence through additive manufacturing
Solution Approach 2:
The patent employs hybrid flow patterns combining parallel and series flow arrangements within the branched channel network, creating a composite flow structure that enhances thermal energy transfer efficiency by leveraging the advantages of both flow configurations
3Device complexity
If conventional heat exchanger designs are used, then structural simplicity is maintained, but pressure drop increases
Solution Approach 1:
The branched channel network with multiple splits and junctures creates dynamic flow paths that adapt to pressure gradients, allowing the system to maintain lower pressure drops across varying operating conditions through the distributed flow distribution architecture enabled by additive manufacturing
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 design achieves reduced pressure drop, increased thermal energy transfer efficiency, and improved structural reliability by optimizing fluid flow and material distribution, while allowing for complex shapes that enhance thermal energy exchange and reduce assembly time.
Implementation Method 1
heat exchangers are utilized to exchange thermal energy from one fluid stream to another fluid stream
Implementation Method 2
thermal energy transfer often occurs between low pressure RAM air and high pressure bleed air
Data Source
AI summary
A heat exchanger includes an external casing and a core. The external casing includes a first inlet, a first outlet, a second inlet, and a second outlet. The core includes an array of branched channels connecting the first inlet and first outlet, an inlet header, and an outlet header. The inlet header is integrally formed with and fluidly connected to the first inlet. The outlet header is integrally formed with and fluidly connected to the first outlet. The branched channels and the external casing define a fluidic passage. The array of branched channels includes a first split, a first juncture, a secondary split, a secondary juncture, and a subset of splits and junctures. The first split and first juncture are common to an entirety of the array of branched channels. The subset of splits and junctures route fluid through interconnections between fluidly parallel branched channels.