Variable Heat Exchanger Passages for Uniform Heat Transfer

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Solution Overview

Problem

Existing heat exchangers exhibit non-uniform heat transfer profiles and thermal gradients, leading to uneven stress distribution and potential structural integrity issues due to varying temperature differences across the exchanger.

Innovation Solution

Modifying the cross-sectional flow area of heat exchanger passages with augmentation features to vary flow rates and velocities, thereby tailoring thermal transfer and reducing thermal stresses through strategic placement of these features.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional uniform flow passages are used, then manufacturing is simple, but heat transfer is non-uniform causing thermal stresses

Engineering Contradiction:
Improvestructural integrityVSAvoidpassage geometry complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies local quality by varying the cross-sectional flow area at specific locations within the heat exchanger passages. Augmentation features are strategically placed to create non-uniform flow distribution, increasing heat transfer coefficients in regions where thermal gradients are most severe. This localized modification optimizes heat transfer where needed without requiring complete redesign of the entire passage geometry, thus improving structural integrity while limiting complexity increases.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent changes geometric parameters of the flow passages by introducing augmentation features that modify the cross-sectional area. These parameter changes alter flow rates and velocities locally, which in turn changes heat transfer coefficients. By adjusting these geometric parameters strategically, the patent achieves more uniform heat transfer distribution and reduces thermal stresses without fundamentally changing the overall device structure.

Inventive Principle:
Principle #35Parameter changes

2Productivity

If flow area is increased uniformly, then heat transfer improves, but thermal gradients and stresses increase

Engineering Contradiction:
Improveheat transfer rateVSAvoidthermal stress
Core Design Contradiction:
ProductivityVSStress or pressure

Solution Approach 1:

Rather than uniformly increasing flow area throughout the heat exchanger, the patent applies local quality by placing augmentation features only in specific regions where thermal gradients are most severe. This selective approach enhances heat transfer rates in critical areas while avoiding uniform area increases that would exacerbate thermal gradients and stresses across the entire structure.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent applies preliminary anti-action by strategically positioning augmentation features to counteract anticipated thermal gradient effects. By pre-positioning these features in regions where thermal stresses are most likely to occur, the design proactively prevents excessive thermal gradient buildup before it can cause structural issues, thus improving heat transfer without proportionally increasing thermal stresses.

Inventive Principle:
Principle #9Preliminary anti-action

3Reliability

If augmentation features are added to improve heat transfer, then thermal transfer improves, but device complexity increases

Engineering Contradiction:
Improveheat transfer uniformityVSAvoidpassage modification complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent limits complexity increases by applying augmentation features only in specific local regions rather than uniformly throughout the entire heat exchanger. This selective placement targets the most critical thermal gradient areas, achieving improved heat transfer uniformity with minimal additional geometric complexity in non-critical regions.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent applies partial action by implementing augmentation features in only the most critical regions where thermal gradients cause the greatest stress, rather than uniformly throughout the entire heat exchanger. This partial modification achieves sufficient heat transfer improvement to reduce thermal stresses without requiring complete redesign of all passages, thus limiting complexity increases while maintaining reliability improvements.

Inventive Principle:
Principle #16Partial or excessive action

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

Achieves a more uniform heat transfer coefficient across the entire heat exchanger, reducing thermal stresses and enhancing structural integrity by optimizing flow characteristics.

Implementation Method 1

the augmentation feature is configured to vary the internal passage flow area and thus improve thermal transfer between hot and cold flows by changing flow rates

Methodology Applied
Scientific EffectFlow rate variation:

Implementation Method 2

As the two working fluids pass through the heat exchanger the hotter working fluid transfers thermal energy to the colder working fluid

Methodology Applied
Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 3

modification of the cross-sectional flow area along the flow passage in order to influence the heat transfer coefficient

Methodology Applied
Scientific EffectHeat transfer coefficient variation:

Data Source

PatentEP4385736B1Variable passages to optimize delta p and heat transfer along flow path
Publication Date: 2026.03.11 RTX CORP
  • EP4385736B1 patent drawingFigure 1
  • EP4385736B1 patent drawingFigure 2
  • EP4385736B1 patent drawingFigure 3~4

AI summary

A heat exchanger including an internal passage extending from a first inlet end to a first outlet end; a first longitudinal length extending from the first inlet end to the first outlet end; an inner surface of the passage including a first augmentation feature disposed along the first longitudinal length across the inner surface; an outer surface extending from a second inlet end to a second outlet end, the outer surface being in heat transfer communication with the inner surface; and a first region including portions of both the inner surface and the outer surface adjacent at least a portion of the first inlet end, wherein the first augmentation feature varies a cross-sectional area in a direction along the first longitudinal length and within the first region.