Counter-flow Heat Exchanger Core with Hollow Vanes
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Solution Overview
Problem
Existing heat exchangers face challenges in achieving improved heat transfer performance, reduced pressure loss, and minimized size and weight, particularly in aircraft engine and environmental control systems.
Innovation Solution
A counter-flow heat exchanger core with a unique configuration that includes a counter-flow arrangement of oil and air flows, non-linear wavy fins, and a manufacturing method using additive manufacturing such as selective laser melting (SLM) to create a single-piece core without brazing or weld joints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional plate/fin construction methods are used, then manufacturing reliability is maintained, but heat transfer performance is limited and size/weight cannot be reduced
Solution Approach 1:
The patent replaces conventional mechanical assembly methods (brazing, welding, mechanical fastening) with additive manufacturing technology. This substitution enables the creation of complex internal geometries and optimized heat transfer surfaces that are impossible to achieve with traditional methods, directly improving heat transfer performance while maintaining manufacturing reliability through a single-piece construction approach.
Solution Approach 2:
The patent utilizes additive manufacturing to achieve precise control over geometric parameters, including non-linear wavy fin profiles, variable thickness sections, and optimized channel configurations. These parameter changes enable enhanced heat transfer efficiency while reducing overall component size and weight compared to conventional designs.
2Productivity
If additive manufacturing is used to create complex geometries, then heat transfer performance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges multiple manufacturing operations and assembly steps into a single additive manufacturing process. The heat exchanger core is produced as one integrated piece with all internal channels, fins, and structural features created in a single build process, eliminating the need for separate machining, assembly, and joining operations despite the geometric complexity.
Solution Approach 2:
The patent replaces complex multi-step mechanical manufacturing and assembly processes with a single additive manufacturing operation. This substitution simplifies the overall manufacturing system by eliminating tooling requirements, assembly fixtures, and quality control steps associated with traditional fabrication methods.
3Device complexity
If single-piece additive manufacturing is used, then assembly complexity is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The additive manufacturing process inherently provides self-alignment and self-joining capabilities. Features such as interference fits, thermal expansion compensation, and flow distribution channels are built-in during the manufacturing process itself, eliminating the need for separate alignment and assembly operations while maintaining precise dimensional tolerances.
Solution Approach 2:
The patent leverages the precise control capabilities of additive manufacturing to achieve tight dimensional tolerances and complex geometric features in a single build process. The manufacturing process parameters are optimized to ensure precision in critical areas while maintaining overall assembly simplicity.
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 counter-flow configuration enhances heat transfer performance, reduces size and weight, and maintains low pressure loss, while the additive manufacturing method allows for complex geometries that improve thermal performance and ease thermal expansion.
Implementation Method 1
forming the heat exchanger core using additive manufacturing, such as selective laser melting
Implementation Method 2
counter-flow heat exchanger core that includes a counter-flow arrangement of oil and air flows
Implementation Method 3
counter-flow arrangement of oil and air flows
Data Source
Figure 1~2
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Figure 6~7
AI summary
A counter-flow heat exchanger core (100) includes a first wall (104) defining a longitudinal axis. The first flow path (106) is defined within the first wall (104). The first flow path (106) includes a primary flow inlet (108) and a primary flow outlet (110) downstream from the primary flow inlet. The heat exchanger core (100) includes at least two hollow vanes (112) circumferentially spaced apart and extending in a radially inward direction from the first wall (104). Each of the at least two hollow vanes (112) includes a first vane wall (114) and a second vane wall (116). The heat exchanger core (100) includes a second flow path (112) defined within the at least two hollow vanes (112) between the first vane wall (114) and second vane wall (116) of each of the at least two hollow vanes (112). The heat exchanger core (100) includes at least one fin extending between two of the at least two circumferentially spaced apart vanes (112).