Counterflow Heat Exchanger with Integrated Scupper Drains
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Heat exchangers in aircraft environmental control systems face efficiency and performance issues due to ice and snow clogging passages, leading to increased pressure losses and reduced performance.
Innovation Solution
A counterflow heat exchanger design with scupper drains and a water removal and air re-entrainment apparatus, utilizing polymeric materials and a bypass heating system to prevent ice ingestion and efficiently remove condensation, allowing for non-traditional material usage and reduced component costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a heat exchanger is used in sub-freezing conditions, then thermal energy exchange is achieved, but ice and snow clog passages causing pressure losses and performance reduction
Solution Approach 1:
The heat exchanger incorporates drains positioned at low points in the core section to proactively remove condensation before it accumulates and freezes into ice blocks that would clog passages. This preliminary removal action prevents the harmful freezing effect before it occurs.
Solution Approach 2:
The patent extracts and removes the harmful condensation/ice formation from the system by providing dedicated drainage pathways. The drains take out the condensed moisture from the first fluid passages, preventing it from accumulating and forming ice blockages that would harm system performance.
2Productivity
If condensation is allowed to accumulate in first fluid passages, then thermal energy exchange continues, but pressure losses increase and performance diminishes
Solution Approach 1:
The drains are strategically positioned to intercept and remove condensation at low points in the first fluid passages before the condensation can accumulate to levels that would significantly increase pressure losses and reduce productivity.
3Loss of energy
If traditional heat exchanger design is used, then thermal energy exchange is achieved, but separate water removal systems are required increasing complexity
Solution Approach 1:
The drainage function is merged directly into the heat exchanger core structure. The drains are integrated into the first fluid passages and core section, combining the thermal exchange and water removal functions into a single unified component, thereby eliminating the need for separate water removal systems.
Solution Approach 2:
The first fluid passages serve multiple functions: they convey the first fluid flow for thermal energy exchange and simultaneously provide pathways for condensation removal through integrated drains. This multi-functionality reduces overall system complexity.
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 design enhances operational efficiency by preventing ice and snow clogging, maintaining performance, and reducing component costs through the use of polymeric materials and integrated drainage systems, eliminating the need for separate water removal systems.
Implementation Method 1
a counterflow heat exchanger configured to exchange thermal energy between a first fluid flow at a first pressure and a second fluid flow at a second pressure less than the first pressure
Implementation Method 2
One or more drains disposed in the core section are operably connected to the plurality of first fluid passages configured to remove condensation from an interior of the first fluid passages
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
A counterflow heat exchanger (10) includes a first fluid inlet (18), a first fluid outlet (20) fluidly coupled to the first fluid inlet (18) via a core section (28), a second fluid inlet (24), and a second fluid outlet (26) fluidly coupled to the second fluid inlet (24) via the core section (28). The core section (28) includes a plurality of first fluid passages (30) configured to convey the first fluid flow (12) from the first fluid inlet (18) toward the first fluid outlet (20), and a plurality of second fluid passages (32) configured to convey the second fluid flow (14) from the second fluid inlet (24) toward the second fluid outlet (26) such that the first fluid flow (12) exchanges thermal energy with the second fluid flow (14) at the core section (28). One or more drains are operably connected to the plurality of first fluid passages (30) configured to remove condensation from an interior of the first fluid passages (30) prior to the condensation reaching the first fluid outlet (20).