Curved Heat Exchanger Segment With Void-Free Bar Joining

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Solution Overview

Problem

In curved heat exchangers used in gas turbine engines, particularly in aerospace applications, the existing design with straight heat transfer segments angularly offset to form a curve results in a pressure drop due to voids between segments, reducing efficiency and performance.

Innovation Solution

The heat transfer segments are designed with enclosure bars that are shaped and arranged to form an angular offset when joined, allowing for a strong and efficient connection without relying solely on welding, thereby eliminating voids and ensuring continuous fluid paths for improved heat transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If straight heat transfer segments are angularly offset to form a curved heat exchanger, then the heat exchanger can fit curved spaces (e.g., aircraft air-intake), but voids form between segments causing pressure drop and reducing efficiency

Engineering Contradiction:

Improveadaptability to curved spacesVSAvoidpressure drop

Core Design Contradiction:

Adaptability or versatilityVSLoss of energy

Solution Approach 1:

The heat exchanger is divided into multiple modular segments that can be angularly offset to form curves. Each segment contains enclosure bars with angularly offset ends that define fluid flow paths, allowing the segmented structure to adapt to curved spaces while maintaining continuous fluid flow through the angularly configured enclosure bars

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The enclosure bars are designed with ends that are angularly offset relative to each other, creating a three-dimensional configuration that eliminates voids between segments. This angular dimensional arrangement allows the fluid flow path to continue smoothly through the curve without pressure loss

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Strength

If segments are joined using welding to achieve strong connections, then structural integrity is improved, but welding defects may be introduced reducing reliability

Engineering Contradiction:

Improvestructural integrityVSAvoidwelding defects

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent replaces the welding process with a mechanical joining system where enclosure bars from adjacent segments engage through their angularly offset ends. This mechanical engagement provides strong structural connections without introducing welding defects, maintaining both strength and reliability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Loss of energy

If voids are eliminated through angularly offset enclosure bars, then pressure drop is reduced, but manufacturing complexity increases

Engineering Contradiction:

Improvepressure dropVSAvoidenclosure bar geometry

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The complex angular configuration is incorporated into individual modular segments during manufacturing. Each segment is produced as a discrete unit with pre-configured angularly offset enclosure bars, allowing the complexity to be managed at the component level rather than requiring complex assembly processes for the entire heat exchanger

Inventive Principle:

Principle #1Segmentation

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

This design enhances the structural integrity and efficiency of the heat exchanger by reducing pressure drops and increasing heat transfer effectiveness through continuous fluid paths and reduced reliance on welding, which can introduce defects.

Implementation Method 1

the enclosure bars of the heat transfer segment may join to corresponding enclosure bars of the adjacent heat transfer segment thus forming an angular offset between the two adjacent heat transfer segments... ensuring continuous fluid paths for improved heat transfer

Methodology Applied

Scientific EffectFluid flow continuity:

Implementation Method 2

Heat transfer segment for a curved heat exchanger... increasing heat transfer effectiveness through continuous fluid paths

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentUS11002491B2Heat transfer segment

Publication Date: 2021.05.11 HS MARSTON AEROSPACE

AI summary

A heat transfer segment for a curved heat exchanger, wherein the heat transfer segment comprises a plurality of enclosure bars that at least partially define two opposite ends of the heat transfer segment, wherein the two opposite ends define respective general planes, characterised in that: the enclosure bars are shaped and arranged such that the general plane of one end of the heat transfer segment is not parallel with the general plane of the other end of the heat transfer segment, such that when said heat transfer segment is joined to an adjacent heat transfer segment in an end-to-end fashion the enclosure bars the heat transfer segment may join to corresponding enclosure bars of the adjacent heat transfer segment.