Counter-Flow Heat Exchanger Core for Low Pressure Loss
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Solution Overview
Problem
Conventional heat exchangers in aircraft engine and environmental control systems face limitations in heat transfer performance, pressure loss, and size/weight reduction, necessitating improved designs.
Innovation Solution
A counter-flow heat exchanger with a core featuring concentric inner and outer walls, corrugated channels that diverge and converge, and additional cylindrical walls to enhance flow distribution and heat transfer, manufactured using additive methods like direct metal laser sintering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional plate/fin construction is used in heat exchangers, then the structure is simple and easy to manufacture, but heat transfer performance is limited and size/weight cannot be reduced
Solution Approach 1:
The heat exchanger core is segmented into multiple flow paths with inner and outer walls creating distinct channels. This segmentation allows independent optimization of each flow path while maintaining overall structural integrity, enabling improved heat transfer performance without sacrificing manufacturability
Solution Approach 2:
The patent transitions from conventional two-dimensional plate/fin construction to a three-dimensional cylindrical core structure with radial and axial flow paths. This dimensional change enables more efficient heat transfer surfaces and better fluid distribution while maintaining manufacturing feasibility through advanced fabrication methods
2Weight of stationary object
If heat exchanger size and weight are reduced, then system integration is improved, but heat transfer performance may deteriorate
Solution Approach 1:
The heat exchanger employs a nested cylindrical structure where inner walls with flow paths are positioned within outer walls, creating concentric channels. This nested arrangement maximizes heat transfer surface area within a compact volume, achieving high performance in a reduced size and weight package
Solution Approach 2:
The patent applies local quality optimization by creating regions of varying wall thickness, channel spacing, and flow path configurations within different sections of the heat exchanger core. This allows concentrated heat transfer enhancement in critical areas while minimizing overall material usage, reducing weight without sacrificing performance
3Productivity
If flow paths are optimized for heat transfer, then heat transfer performance improves, but pressure loss increases
Solution Approach 1:
The heat exchanger incorporates variable cross-sectional areas along the flow paths, with channel spacing and dimensions changing axially and radially. This dynamic geometry optimizes flow velocity and pressure distribution, maintaining high heat transfer coefficients while minimizing pressure losses through carefully designed transitions
Solution Approach 2:
The patent employs parameter changes in the flow path geometry, including varying channel width, height, and curvature along the flow direction. These parameter variations are optimized to balance heat transfer enhancement with pressure loss reduction, achieving both goals simultaneously through computational design
4Productivity
If complex internal structures are added to enhance heat transfer, then heat transfer efficiency improves, but device complexity increases
Solution Approach 1:
The cylindrical core structure serves multiple functions simultaneously: it provides structural support, defines flow paths, enables heat transfer, and facilitates fluid distribution. This multi-functionality reduces the need for separate components, maintaining relative simplicity while achieving high heat transfer efficiency
Solution Approach 2:
The patent merges the functions of multiple walls and partitions into a single integrated cylindrical core structure. The inner and outer walls are combined with internal partitions to create a unified component that performs heat transfer, flow distribution, and structural support, reducing assembly complexity while enhancing 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 design achieves increased heat transfer efficiency, reduced size, and weight, while minimizing pressure loss and maintaining thermal consistency across the heat exchanger, enabling high-temperature and high-pressure operation.
Implementation Method 1
heat exchanger core including an inner wall and an outer wall radially outward and spaced apart from the inner wall
Implementation Method 2
A first flow path is defined within the inner wall and a second flow path is defined between the inner wall and the outer wall
Implementation Method 3
The inner wall defines a first set of channels extending axially from the primary flow inlet to the middle portion of the heat exchanger core diverging away from a radial center of the heat exchanger core
Implementation Method 4
manufactured using additive methods like direct metal laser sintering
Data Source
AI summary
A counter-flow heat exchanger comprising a heat exchanger core including an inner wall and an outer wall radially outward and spaced apart from the inner wall. A first flow path is defined within the inner wall and a second flow path is defined between the inner wall and the outer wall. The heat exchanger core includes a primary flow inlet, a primary flow outlet and a middle portion therebetween. The inner and outer walls are concentric at the primary flow inlet of the heat exchanger core. The inner wall defines a first set of channels extending axially from the primary flow inlet to the middle portion of the heat exchanger core diverging away from a radial center of the heat exchanger core. The inner wall and the outer wall define a second set of channels extending axially from the primary flow inlet to the middle portion of the heat exchanger core converging toward the radial center of the heat exchanger core.