Compact Heat Exchanger Snowflake-Crystal Structure
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Solution Overview
Problem
Conventional manufacturing methods for heat exchangers in aerospace applications are limited in producing complex structures due to shape-formation, spacing, accuracy, and cost constraints, which affects the performance and efficiency of heat transfer.
Innovation Solution
A compact heat exchanger with a core structure approximating a snowflake-crystal design, fabricated using three-dimensional printing, featuring hexagonal channels formed by triangular mini-tubes, which enhances strength-to-weight ratio and heat transfer efficiency while minimizing material usage and pressure drop.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing methods (milling, sheet-bending, extruding) are used, then manufacturing simplicity is maintained, but manufacturing precision and ability to produce complex structures deteriorates
Solution Approach 1:
The patent changes the manufacturing method from conventional subtractive or formative processes (milling, bending, extruding) to additive manufacturing (3D printing). This parameter change enables the production of complex snowflake-crystal structures with high precision that cannot be achieved by traditional methods, while maintaining manufacturing feasibility through automated layer-by-layer construction.
2Device complexity
If complex structures are produced using conventional methods, then structural complexity is increased, but manufacturing cost and difficulty increase
Solution Approach 1:
The patent transforms the manufacturing approach from conventional methods to 3D printing, enabling complex snowflake-crystal structures to be manufactured with relative ease. The additive process naturally accommodates geometric complexity without proportionally increasing manufacturing difficulty, as the machine simply follows digital instructions to deposit material layer by layer.
3Strength
If more material is used to increase strength, then structural strength is improved, but weight and material usage increase
Solution Approach 1:
The patent segments the heat exchanger core into a snowflake-crystal structure composed of multiple triangular mini-tubes arranged in hexagonal channels. This segmentation creates a lattice framework that provides high strength-to-weight ratio, as the distributed triangular elements work together to bear loads while minimizing material usage compared to solid structures.
Solution Approach 2:
The patent employs a composite structural approach by combining multiple mini-tubes into channels, creating a hierarchical composite structure. The snowflake-crystal configuration integrates triangular elements into hexagonal channels, forming a composite lattice that achieves superior strength-to-weight characteristics compared to conventional homogeneous structures.
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 snowflake-crystal structure provides improved cooling efficiency, robustness, and reduced material usage, along with enhanced strength and surface area for heat transfer, overcoming limitations of conventional manufacturing methods and achieving efficient heat transfer and structural integrity.
Implementation Method 1
make a second pass through the mini-tubes to the first manifold such that the fluid is cooled across the mini-tubes
Data Source
AI summary
A compact heat exchanger is provided and includes a first manifold defining an inlet for receiving from a component a fluid to be cooled and an outlet for returning the cooled fluid to the component to cool the component. A second manifold is disposed spaced from the first manifold. A core extends between and fluidly communicates with the manifolds and includes hexagonal channels. Each channel is formed by mini-tubes defining respective triangular passages. A cross-section of the core defines an irregular-cross structure. The fluid enters the inlet of the first manifold, makes a first pass through the mini-tubes to the second manifold, makes a second pass through the mini-tubes to the first manifold such that the fluid is cooled across the mini-tubes, exits the first manifold through the outlet, and returns to the component to cool the component. A method of manufacturing the heat exchanger is provided also.