Interlaced Conduit Heat Exchanger for Stress Management
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Solution Overview
Problem
Heat exchangers in applications like aerospace and automotive face challenges from physical and thermal stresses due to vibration, g-forces, and extreme temperature variations, which require robust structures that add complexity, weight, and expense.
Innovation Solution
A heat exchanger design featuring an interlaced conduit array with multiple fluid flow paths, allowing for stress management through additive manufacturing, enabling robust yet lightweight structures with flexible configuration options.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If robust structures are incorporated in the heat exchanger to resist physical and thermal stress, then stress resistance is improved, but device complexity and weight increase
Solution Approach 1:
The heat exchanger is divided into multiple individual conduits arranged in an array, where each conduit is a separate stress-bearing element. This segmentation allows the structure to distribute and manage stress across multiple independent components rather than requiring a single robust structure, thereby maintaining stress resistance while reducing overall complexity.
Solution Approach 2:
The patent transitions from conventional planar or simple three-dimensional heat exchanger configurations to a multi-dimensional interlaced conduit array structure. The conduits are arranged in multiple layers and orientations (first plurality in first orientation, second plurality in second orientation), creating a spatial network that inherently manages stress through geometric distribution across multiple dimensions, reducing the need for additional robust structural components.
2Reliability
If robust structures are incorporated in the heat exchanger to resist physical and thermal stress, then stress resistance is improved, but weight increases
Solution Approach 1:
By segmenting the heat exchanger into multiple thin-walled conduits rather than using a single thick-walled robust structure, the weight is distributed across many lightweight components. Each conduit can be optimized for minimal weight while collectively providing the required stress resistance through their arranged configuration.
Solution Approach 2:
The interlaced multi-dimensional arrangement of conduits creates a spatial framework that provides structural strength through geometry rather than material quantity. This dimensional arrangement allows the heat exchanger to resist stress with minimal material, significantly reducing weight compared to conventional robust structures.
3Ease of manufacture
If conventional heat exchanger structures are used, then manufacturing is simpler, but adaptability to different stress conditions and applications is reduced
Solution Approach 1:
The interlaced conduit array structure serves multiple functions simultaneously: it provides heat transfer pathways, manages thermal stress through its geometric configuration, resists physical vibration and impact, and can be adapted to various applications (aerospace, automotive, industrial). This multi-functionality is achieved through the versatile interlaced pattern that can be manufactured using additive manufacturing, making the design universally applicable across different stress conditions and industries.
Solution Approach 2:
The patent enables easy modification of design parameters such as conduit diameter, wall thickness, spacing, and interlace pattern through additive manufacturing. These parameter changes allow the heat exchanger to be customized for different stress conditions, thermal loads, and application requirements without changing the fundamental manufacturing process, thus maintaining ease of manufacture while maximizing adaptability.
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 interlaced conduit array design effectively manages stress while maintaining structural integrity and reducing weight, enhancing heat transfer efficiency and flexibility in various applications.
Implementation Method 1
Heat exchangers are devices built for transferring heat from one fluid to another
Implementation Method 2
Such temperature variations can subject heat exchanger components to thermally-induced stress
Implementation Method 3
the digital model is inputted into an additive manufacturing apparatus or system comprising an energy source, and formed by repeatedly applying energy from the energy source to fuse successively applied incremental quantities of a fusible material corresponding to the digital model of the heat exchanger
Data Source
AI summary
A heat exchanger is disclosed including an array of interlaced conduits. The conduit array includes a first plurality of conduits connected to a first inlet header at one end of the first plurality of conduits and to a first outlet header at an opposite end of the first plurality of conduits. This first plurality of conduits provides a first fluid flow path from the first inlet header through the first plurality of conduits to the first outlet header. The conduit array also includes a second plurality of conduits crossing and interlaced with the first plurality of conduits. First and second fluid flow paths are provided through the first and second pluralities of conduits, and a third fluid flow path is through open spaces between the crossed interlaced first and second pluralities of conduits.