Finned Heat Exchanger Plate Trimming for Aircraft Cooling
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Solution Overview
Problem
Existing gas turbine engine heat exchangers face inefficiencies due to the heating of air during compression, which reduces its cooling effectiveness, and the need for improved heat transfer mechanisms in aircraft power and thermal management systems.
Innovation Solution
A method involving the formation of heat exchanger plates with progressively varying fin heights and orientations, secured by brazing, and utilizing electro-discharge machining to trim wave form metallic sheets, allowing for efficient heat transfer between air flows in gas turbine engines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If air is compressed for cooling purposes, then the air temperature increases, but the cooling effectiveness decreases
Solution Approach 1:
The patent applies parameter changes by modifying the physical state and properties of air through compression, then using heat exchangers to change its temperature parameters back down, restoring its cooling effectiveness for turbine blade cooling applications
2Power
If wave form metallic sheets are secured to heat exchanger plate substrates, then heat transfer efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The wave form metallic sheets are pre-formed with corrugated patterns before being attached to the plate substrates. This preliminary formation of the heat transfer surfaces allows for optimized heat transfer geometry to be established in advance, improving heat transfer efficiency while separating the complexity of wave formation from the final assembly process
Solution Approach 2:
The patent employs electro-discharge machining (EDM) to trim and shape the wave form metallic sheets, replacing traditional mechanical cutting methods. This substitution provides more precise control over the wave form geometry and enables complex corrugated patterns to be created with higher accuracy and surface quality
3Manufacturing precision
If peaks of wave form sheets are removed, then fin spacing and orientation control is improved, but manufacturing time increases
Solution Approach 1:
Electro-discharge machining (EDM) is used to remove peaks from wave form metallic sheets, replacing traditional mechanical cutting or grinding methods. This substitution enables precise control over fin spacing and orientation through programmable electrode paths, achieving high manufacturing precision while reducing the time required compared to iterative mechanical adjustments
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
Enhances heat transfer efficiency by accommodating progressive changes in plate orientation and fin spacing, improving cooling effectiveness and thermal management in gas turbine engines.
Implementation Method 1
heat exchanger plate for providing heat transfer between a first flow along a first flowpath and a second flow along a second flowpath
Implementation Method 2
heat transfer between air flows in gas turbine engines
Implementation Method 3
utilizing electro-discharge machining to trim wave form metallic sheets
Implementation Method 4
secured by brazing
Data Source
AI summary
A method for forming a heat exchanger plate includes: securing a wave form metallic sheet to a heat exchanger plate substrate, the substrate comprising a first face and a second face opposite the first face, the securing of the wave form metallic sheet being to the first face; and removing peaks of the sheet.