Heat Exchanger Flow Management Assembly for Lower Pressure Drop
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Solution Overview
Problem
Conventional counter-flow heat exchangers face limitations in heat transfer performance, pressure loss, size, and weight due to traditional plate fin constructions, which hinder high-temperature applications and system integration, and struggle with efficient fluid flow transitions that impact overall performance.
Innovation Solution
A fluid flow management assembly that reduces pressure drop by using layered slot structures with larger cross-sectional areas transitioning from a main inlet to the core section, merging back into pipes, and incorporating vanes to manipulate fluid flow, allowing for a more compact and efficient heat exchanger design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional plate fin construction is used, then heat transfer performance can be achieved, but pressure loss increases and size and weight increase
Solution Approach 1:
The heat exchanger is divided into multiple channels arranged in parallel, with each channel containing a fluid management assembly. This segmentation allows independent optimization of flow paths, reducing overall pressure loss while maintaining heat transfer effectiveness through distributed thermal exchange surfaces.
Solution Approach 2:
The patent introduces a multi-dimensional fluid management structure with layered slots and three-dimensional channel arrangements. The fluid flow transitions from two-dimensional plate fin surfaces to three-dimensional channel flow, enabling improved heat transfer performance with reduced pressure drop through optimized flow distribution in multiple spatial dimensions.
2Ease of operation
If conventional headering techniques are used for fluid transition, then pipe flow to layered arrangement transition is achieved, but overall performance significantly impacts negatively
Solution Approach 1:
The fluid management assembly incorporates preliminary flow distribution features at the inlet, including distributed slot openings and flow straightening elements positioned before the main heat transfer channels. This preliminary action ensures uniform flow distribution across all channels from the start, preventing performance degradation from poor flow transition.
Solution Approach 2:
The patent introduces an intermediary fluid management structure consisting of layered slots and transition channels that mediate between the inlet pipe flow and the heat transfer channels. This intermediary structure smoothly transitions the flow from pipe configuration to layered channel arrangement, maintaining overall performance while enabling operational flexibility.
3Ease of operation
If pipe flow transitions to layered arrangement, then fluid distribution is achieved, but pressure drop increases
Solution Approach 1:
The fluid management assembly employs dynamic flow distribution features including adjustable slot configurations and flow direction control elements. These dynamic features adapt the flow pattern to minimize pressure drop while achieving uniform distribution across the layered channels, allowing optimization of both fluid distribution and pressure characteristics.
4Productivity
If traditional heat exchanger design is used, then basic heat transfer is achieved, but size and weight increase
Solution Approach 1:
The patent utilizes thin-walled channel structures and film-like thermal exchange surfaces within the fluid management assembly. These thin-film structures provide adequate heat transfer performance while significantly reducing the overall weight of the heat exchanger compared to traditional robust plate fin constructions.
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
This solution reduces pressure drop, minimizes size and weight, enhances structural reliability, and improves heat transfer performance by maintaining constant flow area and reducing stress through symmetric flow distribution and thermal capacitance management.
Implementation Method 1
A fluid flow management assembly that reduces pressure drop by using layered slot structures with larger cross-sectional areas transitioning from a main inlet to the core section
Implementation Method 2
improves heat transfer performance by maintaining constant flow area and reducing stress through symmetric flow distribution and thermal capacitance management
Implementation Method 3
Heat exchangers are central to the functionality of numerous systems in engines and environmental controls systems
Data Source
Figure 1
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AI summary
A heat exchanger includes a core section (18) defining a plurality of first fluid channels and a plurality of second fluid channels. The heat exchanger also includes a header section (16) defining a plurality of first fluid layers (30) and a plurality of second fluid layers (32). The heat exchanger further includes a transition region (36) located between the header section and the core section, the transition region fluidly coupling the plurality of first fluid layers to the first fluid channels, each of the first fluid layers routing a first fluid to a respective group of first fluid channels.