3D Lattice Heat Exchanger Baffles for Lower Pressure Loss
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Solution Overview
Problem
Conventional heat exchangers face challenges in manufacturing complex baffle configurations, leading to suboptimal performance, fluid cross-contamination, and structural issues due to complicated fabrication processes, especially when integrating baffles into three-dimensional lattice structures, which also result in significant pressure drops and shear stress.
Innovation Solution
The development of heat exchangers with integrally formed contiguous unit cells defining a three-dimensional lattice structure, incorporating pathway cells and baffle cells that allow for customized flow passages and reduced pressure loss through rounded unit cell entrances, enabling improved manufacturability and heat transfer properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional baffles are fabricated using panels with holes fitted over tubes and welded in place, then baffles can direct fluid flow and support tube bundles, but the fabrication process becomes complicated and time-consuming, leading to simple baffle configurations and potential leaks or stress points from fabrication errors
Solution Approach 1:
The baffle and tube bundle are merged into a single integrated structure where the baffle is formed as one piece with the tube bundle, eliminating separate fabrication and assembly steps. This integration removes welding operations and hole-fitting processes, thereby improving reliability by eliminating potential leak paths and stress concentration points while dramatically simplifying manufacturing.
Solution Approach 2:
The baffle structure is segmented into multiple modular components that can be manufactured separately and then assembled through simpler connection methods. This segmentation allows for easier manufacturing of complex baffle configurations while maintaining structural integrity and reliability, avoiding the need for complicated welding of large monolithic baffles.
2Ease of operation
If baffles are added to three-dimensional lattice structures, then fluid flow can be directed and regulated, but the fabrication complexity increases significantly due to the complicated configuration of the lattice structure
Solution Approach 1:
The baffle elements are merged directly into the three-dimensional lattice structure as integral components rather than separate add-ons. This integration maintains the complex lattice configuration for optimal fluid flow control while simplifying fabrication by creating the baffle-lattice assembly as a unified structure, reducing the number of discrete parts and assembly operations.
Solution Approach 2:
The baffle functionality is implemented by utilizing the three-dimensional space within the lattice structure, creating flow regulation features that extend in multiple dimensions rather than relying solely on two-dimensional baffle panels. This dimensional approach allows for effective fluid control while maintaining structural integrity and simplifying the overall fabrication process.
3Temperature
If tube bundles are used in conventional heat exchangers, then heat transfer can occur between fluids, but the abrupt transition from inlet plenum to tube bundle causes significant shear stress and pressure drop
Solution Approach 1:
The inlet transition region is designed with curved, rounded surfaces instead of abrupt sharp edges. This curvature allows for gradual flow acceleration and redirection into the heat transfer channels, reducing shear stress and pressure drop while maintaining effective heat transfer. The smooth transitions minimize flow separation and turbulence that would otherwise increase energy losses.
4Ease of manufacture
If simple baffle configurations are used due to fabrication constraints, then manufacturing becomes easier, but heat exchanger performance becomes suboptimal and fluid cross-contamination may occur
Solution Approach 1:
The integration of baffles with the tube bundle or lattice structure eliminates the need for complex separate baffle fabrication while maintaining or improving performance. The merged structure inherently provides proper flow separation and direction without requiring additional fabrication steps, thereby achieving both ease of manufacture and high reliability simultaneously.
Solution Approach 2:
The integrated baffle-structure serves multiple functions simultaneously: it directs fluid flow, provides structural support, and prevents cross-contamination between fluid streams. This multi-functionality is achieved through a single fabrication process, making complex high-performance configurations as manufacturable as simple designs while significantly improving heat exchanger reliability.
Data Source
AI summary
Provided are heat exchangers that have a plurality of integrally formed contiguous unit cells defining a three-dimensional lattice of repeating unit cells, and methods of forming a baffle in a three-dimensional lattice structure of a heat exchanger. The plurality of integrally formed contiguous unit cells include a plurality of pathway cells and a plurality of baffle cells integrally formed among the plurality of pathway cells. The plurality of pathway cells have a solid domain that includes interior and exterior pathway-cell surfaces that respectively contiguously define first and second furcated fluid domains for a first fluid and a second fluid to respectively flow across the plurality of pathway cells. The plurality of baffle cells have a solid domain that includes one or more furcated-pathway blinds that together provide one or more furcated-pathway baffles that contiguously define a boundary to a furcated fluid domain.