Intertwined Tortuous Conduits for Thermal Management
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Solution Overview
Problem
Existing heat exchangers face increased manufacturing costs and fluid flow resistance due to the need for additional mechanical power to drive fluids through tightly packed fins, which compromise the flow of the second fluid.
Innovation Solution
A thermal management system featuring a conduit assembly with plural fluidly separate conduits that extend along tortuous paths, intertwined with each other, allowing for enhanced thermal energy transfer without compromising fluid flow, and optionally including arms to maintain conduit positions and structures for improved stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If fins are tightly packed to enhance heat transfer area, then heat transfer efficiency is improved, but fluid flow resistance increases requiring additional mechanical power
Solution Approach 1:
The patent employs tortuous (curved) conduit paths instead of straight lines, allowing the conduits to intertwine and pack more efficiently in three-dimensional space. This curvature enables greater heat transfer surface area within the same volume without proportionally increasing flow resistance, as the curved paths naturally guide fluid flow while maximizing thermal interaction with the surrounding medium.
Solution Approach 2:
The patent transitions from two-dimensional fin packing to three-dimensional intertwined conduit arrangements. By utilizing the third dimension (depth/volume) through tortuous paths that wind through the heat exchanger body, the system achieves superior heat transfer efficiency without the linear density issues of tightly packed fins, reducing the mechanical power needed to drive fluid flow.
2Strength
If multiple separate components (tubes, fins, body) are assembled with individual positioning and joining, then structural strength is achieved, but manufacturing time and costs increase
Solution Approach 1:
The patent merges the body and conduit assembly into a single integrated component formed by additive manufacturing. This consolidation eliminates the need for separate tubes, fins, and body parts that would require individual positioning, orientation, and joining through fastening, brazing, or welding. The single-piece construction maintains structural strength while dramatically reducing manufacturing steps, time, and costs.
Solution Approach 2:
The patent employs additive manufacturing technology to change the manufacturing process parameters from traditional subtractive or assembly-based methods. This manufacturing paradigm shift enables the creation of complex intertwined conduit geometries within a single monolithic structure, achieving both structural integrity and manufacturing efficiency simultaneously.
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 system achieves thermal energy transfer comparable to or greater than that of fin-based systems while reducing fluid flow resistance, enabling more efficient heat exchange with smaller conduit cross-sections and potentially lower manufacturing costs through additive manufacturing.
Implementation Method 1
exchanges thermal energy with the first fluid that moves within each of the plural conduits
Implementation Method 2
a first fluid at a relatively high temperature may pass through a first passageway, and a second fluid at a relatively low temperature may pass through a second passageway
Data Source
AI summary
A thermal management system and method includes a body having an inlet and an outlet configured to direct a first fluid into and out of the body. The body incudes a channel that is fluidly separate from the inlet and the outlet. A second fluid is directed through the channel. A conduit assembly is fluidly coupled with the inlet and the outlet. The conduit assembly includes plural fluidly separate conduits. Each of the plural conduits extend between a corresponding first end and a corresponding second end along a corresponding tortuous path. The plural conduits are intertwined with each other between the first ends and the second ends. The plural conduits are positioned such that the second fluid flowing through the channel passes over the plural conduits and exchanges thermal energy with the first fluid that moves within each of the plural conduits.