Heat Exchanger Cross-Channel Flow for FOD Blockage Mitigation

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Solution Overview

Problem

Heat exchangers in vehicles like aircraft face efficiency losses due to foreign object debris (FOD) constriction or blockage, which cannot be mitigated by increasing flow channel size without compromising weight and size constraints.

Innovation Solution

Incorporating fins with apertures that allow cross-channel fluid communication to maintain efficiency by enabling fluid flow between channels even when one inlet is constricted by FOD.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the heat exchanger is designed with larger flow channels to prevent FOD blockage, then reliability is improved, but weight and size increase

Engineering Contradiction:

Improveresistance to FOD blockageVSAvoidheat exchanger weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The heat exchanger is divided into multiple flow channels separated by fins. Each channel is a separate pathway that can be independently blocked or remain open, allowing the system to maintain functionality through alternative routes rather than requiring a single large channel.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Apertures in the fins serve as intermediary pathways that allow fluid to bypass blocked sections. These small openings in the fin structures provide alternative flow routes when main channels are constricted by FOD, maintaining system reliability without requiring oversized channels.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If the heat exchanger size is increased to accommodate larger flow channels, then reliability is improved, but the device becomes too large for vehicle installation

Engineering Contradiction:

Improveresistance to FOD blockageVSAvoidheat exchanger volume

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The heat exchanger volume is segmented into multiple smaller flow channels rather than one large channel. This segmentation allows the overall device to maintain a compact form factor while providing multiple independent pathways that resist blockage, as FOD particles are less likely to block all segmented channels simultaneously.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent utilizes the dimensional space within existing fin structures by incorporating apertures through the fin thickness. This adds a third-dimensional flow pathway (through the fin) without increasing the planar footprint of the heat exchanger, allowing bypass capability within the existing volume envelope.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Reliability

If multiple apertures are added to fins for cross-channel communication, then reliability is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvecross-channel flow capabilityVSAvoidfin manufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The fins are designed with porous or perforated structures containing multiple apertures. This approach integrates the bypass capability directly into the fin material structure, allowing cross-channel flow while maintaining manufacturing simplicity through established porous material fabrication techniques rather than requiring complex assembly of separate components.

Inventive Principle:

Principle #31Porous materials

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 solution maintains heat exchanger efficiency and reduces weight by allowing fluid to bypass constricted channels, minimizing thermal performance losses and FOD accumulation.

Implementation Method 1

a fin separating the first flow channel from the second flow channel, wherein the fin defines at least one aperture configured to allow fluid to flow between the first flow channel and the second flow channel

Methodology Applied

Scientific EffectFluid flow through aperture:

Implementation Method 2

adjacent flow channels separated by a fin

Methodology Applied

Scientific EffectHeat transfer:

Data Source

PatentUS12405064B2Heat exchanger including cross channel communication

Publication Date: 2025.09.02 HONEYWELL INTERNATIONAL INC

AI summary

In some examples, a heat exchanger includes a first flow channel having a first flow channel inlet and a first flow channel outlet. The heat exchanger also includes a second flow channel having a second flow channel inlet and a second flow channel outlet. A fin may separate the first flow channel from the second flow channel. The fin may define at least one aperture configured to allow fluid to flow between the first flow channel and the second flow channel if one of the first flow channel inlet or second flow channel inlet becomes constricted through a buildup of foreign object debris.