Heat Exchanger Inlet Header with Embedded Cooling Channels
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Solution Overview
Problem
Heat exchangers used in high temperature and high pressure environments, such as gas turbine engines, experience stresses due to differing thermal expansion characteristics between various sections, leading to potential failure or limited life.
Innovation Solution
A heat exchanger design that includes a heat exchanger core with a cold side and a hot side, coupled with an inlet header that has a cooling channel surrounding the inlet duct. This configuration allows for the directed flow of hot and cooling fluids, while the cooling channel reduces thermal stresses by cooling the inlet header.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the inlet header is exposed to hot fluid flow, then the heat exchanger can transfer heat effectively, but the inlet header experiences greater thermal expansion than the heat exchanger core
Solution Approach 1:
The patent applies local quality by providing cooling channels specifically in the inlet header region that is subject to high thermal expansion, while other parts of the heat exchanger operate without such cooling. This localized cooling approach addresses the thermal expansion issue only where it occurs most severely, maintaining temperature differences necessary for heat transfer in other regions.
Solution Approach 2:
The inlet header is segmented into regions with different thermal management characteristics. The first region contains cooling channels that receive cooling fluid to reduce thermal expansion, while the second region operates without active cooling to maintain heat transfer efficiency. This segmentation allows different parts of the same component to have different thermal properties.
2Reliability
If cooling channels are added to the inlet header, then thermal stresses are reduced, but the device complexity increases
Solution Approach 1:
The cooling channels are merged into the inlet header structure itself, forming an integrated component. The inlet header combines both the hot fluid passage function and the cooling fluid passage function in a single integrated structure, eliminating the need for separate cooling devices and reducing overall system complexity.
Solution Approach 2:
The inlet header serves multiple functions: it distributes hot fluid to the heat exchanger core, provides structural support, and contains cooling channels for thermal management. This multi-functionality reduces the need for additional components and simplifies the overall system architecture.
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 described heat exchanger effectively reduces thermal stresses by cooling the inlet header, thereby extending the useful life and preventing failure of the heat exchanger in high-temperature, high-pressure environments.
Implementation Method 1
The interior wall and exterior wall define a cooling channel surrounding at least a portion of the inlet duct, which is configured to direct the hot fluid though the inlet header to the hot side when the heat exchanger is in operation. The cooling channel is configured to direct a second cooling fluid through the cooling channel when the heat exchanger is in operation.
Implementation Method 2
the different sections or parts of the heat exchanger are exposed to extreme temperature differences which cause the different sections or parts of the heat exchanger to have differing thermal expansion characteristics
Implementation Method 3
The cold side is configured to direct a first cooling fluid from the cold inlet to the cold outlet when the heat exchanger is in operation. The hot side is configured to direct a hot fluid from the hot inlet to the hot outlet when the heat exchanger is in operation.
Data Source
AI summary
A heat exchanger includes a heat exchanger core including a cold side and a hot side. The cold side directs a first cooling fluid from a cold inlet to a cold outlet. The hot side directs a hot fluid from a hot inlet to a hot outlet. An inlet header coupled to the hot side of the heat exchanger core at the hot inlet includes an interior wall and an exterior wall spaced apart from the interior wall. The interior wall defines an inlet duct; the interior wall and exterior wall define a cooling channel surrounding at least a portion of the inlet duct. The inlet duct directs hot fluid though the inlet header to the hot side. The cooling channel directs a second cooling fluid through the cooling channel.