Counter-Flow Heat Exchanger Core for Low Pressure Loss
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Solution Overview
Problem
Conventional heat exchangers in engine and environmental control systems of aircraft require improvements in heat transfer performance, pressure loss reduction, and size/weight reduction.
Innovation Solution
A cylindrical counter-flow heat exchanger with a core featuring concentric inner and outer walls, alternating channels, and additional cylindrical walls, manufactured via additive manufacturing, to enhance heat transfer and reduce size and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional plate/fin construction is used in heat exchangers, then structural simplicity is maintained, but heat transfer performance is insufficient and pressure loss is high
Solution Approach 1:
The heat exchanger core is segmented into multiple alternating channels formed by corrugated inner walls, creating a multi-pass flow path that enhances heat transfer while distributing pressure drop across multiple segments. The segmentation of flow paths into first and second alternating channels allows for improved thermal exchange between hot and cold fluids.
Solution Approach 2:
The patent employs curved and corrugated surface geometries in the inner walls to form alternating channels. The curved surfaces increase the effective heat transfer area and promote turbulent flow patterns that enhance heat transfer coefficients while reducing pressure loss compared to conventional flat plate/fin constructions.
2Temperature
If conventional plate/fin construction is used, then manufacturing simplicity is maintained, but heat transfer performance requires continual improvement
Solution Approach 1:
The patent changes the geometric parameters of the heat exchanger channels by using corrugated inner walls with specific wave patterns and alternating channel configurations. These parameter changes optimize heat transfer performance while the additive manufacturing process enables production of these complex geometries without proportionally increasing manufacturing complexity.
Solution Approach 2:
The patent replaces conventional mechanical assembly of plate/fin components with additive manufacturing technology. This substitution allows for the creation of complex internal channel geometries and corrugated structures in a single integrated manufacturing step, eliminating the need for multiple separate components and assembly operations.
3Weight of stationary object
If heat exchanger size and weight are reduced, then system integration is improved, but heat transfer performance and pressure loss characteristics must be optimized
Solution Approach 1:
The patent utilizes three-dimensional corrugated channel structures that extend in multiple spatial dimensions, maximizing heat transfer surface area within a compact volume. The alternating channels are arranged in a three-dimensional pattern that increases effective heat exchange area without proportionally increasing the overall heat exchanger size or weight.
Solution Approach 2:
The heat exchanger design features nested concentric cylindrical walls with alternating channels formed between them. The inner corrugated wall is nested within the outer cylindrical wall, creating multiple flow paths in a compact nested arrangement that reduces overall size and weight while maintaining effective heat transfer 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 improved heat transfer performance, reduced pressure loss, and smaller size while maintaining structural integrity and efficiency.
Implementation Method 1
A counter-flow heat exchanger includes a heat exchanger core that defines a first flow path within an inner wall and a second flow path between the inner wall and an outer wall
Data Source
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AI summary
A counter-flow heat exchanger (100) comprising a heat exchanger core (102) including an inner wall (110) and an outer wall (112) radially outward and spaced apart from the inner wall (110). A first flow path (114) is defined within the inner wall (110) and a second flow path (116) is defined between the inner wall (110) and the outer wall (112). The heat exchanger core (102) includes a primary flow inlet (104), a primary flow outlet (106) and a middle portion (108) therebetween. The inner and outer walls (110, 112) are concentric at the primary flow inlet (104) of the heat exchanger core (102). The inner wall (110) defines a first set of channels (118) extending axially from the primary flow inlet (104) to the middle portion (108) of the heat exchanger core (102) diverging away from a radial center of the heat exchanger core (102). The inner wall (110) and the outer wall (112) define a second set of channels (120) extending axially from the primary flow inlet (104) to the middle portion (108) of the heat exchanger core (102) converging toward the radial center of the heat exchanger core (102). The heat exchanger core is a circular cylinder, wherein at the primary flow inlet of the heat exchanger core, in a cross-section taken perpendicular to a primary flow direction, the inner and outer walls define an annulus therebetween including the second flow path. A diameter of the heat exchanger core at the primary flow inlet is smaller than a diameter of the heat exchanger core in the middle portion.