Heat Exchanger Header Dome Cavity Flow Transition
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Solution Overview
Problem
Designing heat exchanger headers that can withstand ultra-high operating pressures and temperatures while maintaining compactness and efficient heat transfer is challenging, especially when integrating these headers within systems requiring intricate header topologies.
Innovation Solution
A transition structure for heat exchanger headers featuring a dome cavity that transitions flow between a single first channel and multiple second channels, allowing for efficient fluid communication and stress distribution, which can be additively manufactured without internal supports.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional header topologies are used to connect heat exchanger channels to external plumbing, then the heat exchanger can withstand operating pressures, but the header structure becomes complex and difficult to manufacture
Solution Approach 1:
The patent merges the header structure with the heat exchanger core by integrating manifolds directly into the heat exchanger body, eliminating separate header components and reducing overall complexity while maintaining pressure withstanding capability
Solution Approach 2:
The heat exchanger header is designed to perform multiple functions: it serves as both the structural component for pressure containment and the flow distribution manifold, combining header and manifold functions into a single integrated structure
2Weight of stationary object
If compact heat exchanger designs are implemented, then size and weight are reduced, but the header topology becomes more intricate to accommodate high pressure conditions
Solution Approach 1:
The patent employs curved and domed header geometries instead of sharp angles and flat surfaces, distributing stress more evenly across the structure and allowing for lighter weight construction while maintaining pressure integrity in compact designs
Solution Approach 2:
The header design utilizes three-dimensional curved pathways and domed cavities to route fluid flow, replacing traditional two-dimensional planar manifolds and enabling more efficient space utilization in compact heat exchangers
3Ease of manufacture
If additive manufacturing is used to create intricate header topologies, then complex structures can be manufactured, but buildability constraints add complexity to the design process
Solution Approach 1:
The patent designs header structures with built-in support features and optimized build orientations from the outset, incorporating preliminary considerations for additive manufacturing constraints into the design phase to simplify the manufacturing process
Solution Approach 2:
The header geometry is designed to be self-supporting during additive manufacturing, with overhanging features minimized and build orientations selected to eliminate the need for complex support structures, allowing the part to manufacture itself without additional assistance
Data Source
AI summary
In accordance with at least one aspect of this disclosure, a transition structure for a heat exchanger can include a body defining a dome cavity. The dome cavity can be configured to transition flow between at least one first channel and a plurality of second channels having a different number than the at least one first channel.