Diverging-Core Heat Exchanger for Lower Pressure Drop

Solution Overview

Problem

Existing heat exchangers in aircraft face challenges in achieving a lightweight, space-efficient design that meets heat rejection demands while minimizing pressure drop and drag, and traditional designs often require motivators to manage fluid flow, increasing overall weight and drag.

Innovation Solution

The design of a heat exchanger with diverging cores that reduce pressure drop and weight by allowing fluids to flow through isolated paths, featuring a housing with a square cross-section and angled cores that diverge towards the inlet or outlet, reducing the need for motivators and minimizing drag.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If traditional heat exchanger designs are used, then heat rejection demand is met, but weight and size requirements are not satisfied

Engineering Contradiction:

Improveheat rejectionVSAvoidheat exchanger weight

Core Design Contradiction:

TemperatureVSWeight of stationary object

Solution Approach 1:

The heat exchanger is divided into multiple discrete cores (first core, second core, third core, fourth core) that are arranged in a segmented pattern around the fluid flow path. Each core handles a portion of the heat exchange independently, allowing for optimized weight and size while maintaining overall heat rejection performance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cores are arranged in a three-dimensional configuration around the fluid flow path rather than in a traditional linear or planar arrangement. This spatial distribution optimizes heat transfer efficiency while minimizing the overall weight and footprint of the heat exchanger assembly.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Temperature

If traditional heat exchanger designs are used, then heat rejection demand is met, but installation volume is excessive

Engineering Contradiction:

Improveheat rejectionVSAvoidinstallation volume

Core Design Contradiction:

TemperatureVSVolume of stationary object

Solution Approach 1:

The heat exchanger is divided into multiple discrete cores (first core, second core, third core, fourth core) that are arranged in a segmented pattern around the fluid flow path. Each core handles a portion of the heat exchange independently, allowing for optimized weight and size while maintaining overall heat rejection performance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The multiple cores are nested or arranged concentrically around the fluid flow path, with each core positioned in relation to the others in a compact configuration. This nesting approach maximizes heat transfer surface area within a minimal installation volume.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Temperature

If traditional heat exchanger designs are used, then cooling performance is achieved, but pressure drop increases drag

Engineering Contradiction:

Improvecooling performanceVSAvoiddrag

Core Design Contradiction:

TemperatureVSObject-generated harmful factors

Solution Approach 1:

The heat exchanger is divided into multiple discrete cores (first core, second core, third core, fourth core) that are arranged in a segmented pattern around the fluid flow path. Each core handles a portion of the heat exchange independently, allowing for optimized weight and size while maintaining overall heat rejection performance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cores are arranged in a three-dimensional configuration around the fluid flow path rather than in a traditional linear or planar arrangement. This spatial distribution optimizes heat transfer efficiency while minimizing the overall weight and footprint of the heat exchanger assembly.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 diverging core design results in a smaller, lighter heat exchanger with improved thermal performance and reduced pressure drop, leading to lower drag and weight savings of up to 60% compared to traditional designs.

Implementation Method 1

a plurality of heat exchanger cores within the housing, wherein the plurality of heat exchanger cores meet at a junction and diverge

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Implementation Method 2

one or more first flow paths through which the first fluid can pass through the heat exchanger cores

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentEP4256266B1Heat exchanger

Publication Date: 2025.07.16 BAE SYSTEMS PLC

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AI summary

There is provided a heat exchanger comprising: a housing comprising: an inlet at a proximal end for receiving a first fluid; and an outlet, downstream of the inlet at the distal end of the housing, through which the fluid is configured to exit the housing; and a plurality of heat exchanger cores within the housing, wherein the plurality of heat exchanger cores meet at a junction and diverge from each other towards one of the inlet or the outlet of the housing; wherein the plurality of heat exchanger cores comprises a plate fin arrangement; and, wherein the plurality of heat exchanger cores comprise one or more first flow paths through which the first fluid can pass through the heat exchanger cores, in use.