Layered Diffuser-Channel Heat Exchanger for Lower Pressure Loss

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Solution Overview

Problem

Aerospace applications face challenges in managing fluid pressure drop and minimizing pressure losses in heat exchangers while reducing the power demands and overall footprint of heat exchanger systems, particularly in aircraft cabin cooling and refrigeration systems.

Innovation Solution

A layered diffuser-channel heat exchanger design featuring alternating diffuser fins and fluid channel layers, integrated with a blower having rotating blades and stationary vanes, optimized for airflow direction and diffuser fin geometry, formed using additive manufacturing to enhance heat transfer efficiency and reduce fan power requirements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If external fans are used to drive airflow and increase heat transfer coefficient, then heat transfer efficiency is improved, but power demands and overall footprint increase

Engineering Contradiction:

Improveheat transfer coefficientVSAvoidpower demands

Core Design Contradiction:

TemperatureVSUse of energy by stationary object

Solution Approach 1:

The heat exchanger channels are designed with self-induced airflow capability through integrated blowers and diffuser fins that generate airflow without requiring external fans, thereby reducing power consumption while maintaining heat transfer efficiency

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent modifies the airflow parameters by using variable pitch diffuser fins and optimized channel geometries to enhance heat transfer coefficients without proportionally increasing power demands, achieving efficient heat exchange at lower power levels

Inventive Principle:

Principle #35Parameter changes

2Temperature

If external fans are used to drive airflow and increase heat transfer coefficient, then heat transfer efficiency is improved, but overall footprint increases

Engineering Contradiction:

Improveheat transfer coefficientVSAvoidoverall footprint

Core Design Contradiction:

TemperatureVSArea of stationary object

Solution Approach 1:

The blower and diffuser fin assemblies are integrated directly into the heat exchanger channel structure, merging previously separate components (fan, housing, channels) into a unified compact assembly that reduces overall footprint while maintaining heat transfer performance

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent employs nested arrangements where diffuser fins are positioned within channel structures and blowers are integrated into the channel assembly, creating a compact nested configuration that minimizes the overall footprint of the heat exchanger system

Inventive Principle:

Principle #7Nested doll (Nesting)

3Stress or pressure

If fluid pressure drop through channels is not carefully managed, then pressure losses increase, but heat transfer efficiency may be compromised

Engineering Contradiction:

Improvepressure lossesVSAvoidheat transfer efficiency

Core Design Contradiction:

Stress or pressureVSTemperature

Solution Approach 1:

The diffuser fins are designed with varying pitch angles and geometries at different locations within the channels to locally optimize airflow characteristics, reducing pressure losses in high-resistance areas while maintaining heat transfer efficiency in other regions

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent employs dynamic airflow management through variable pitch diffuser fins that adapt to different operating conditions, optimizing the balance between pressure loss reduction and heat transfer maintenance across varying airflow rates and thermal loads

Inventive Principle:

Principle #15Dynamics

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 achieves improved heat transfer coefficients and reduced pressure losses, allowing for lower fan power consumption and a smaller footprint compared to traditional systems, while maintaining effective airflow management.

Implementation Method 1

A layered diffuser-channel heat exchanger includes a first fluid channel layer having a first fluid channel located between a first surface and a second surface of the first fluid channel layer, a plurality of first diffuser fins extending from the first surface of the first fluid channel layer

Methodology Applied

Scientific EffectDiffuser effect: Diffusion

Implementation Method 2

Many aerospace applications, such as aircraft cabin cooling systems and/or aircraft refrigeration systems, employ heat exchangers to remove heat from an airflow

Methodology Applied

Scientific EffectHeat transfer: Convection

Implementation Method 3

remove heat from an airflow. The airflow may flow through one or more heat exchanger channels during the heat exchange process

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentEP4145081B1Layered diffuser channel heat exchanger

Publication Date: 2025.10.29 BE AEROSPACE INC

Figure 1A
Figure 1B
Figure 2A

AI summary

A layered diffuser-channel heat exchanger may comprise a plurality of fluid channel layers (104) and a plurality of diffuser fin layers (102) interleaved with the plurality of fluid channel layers. Each fluid channel layer of the plurality of fluid channel layers may have a first surface (106), a second surface (108) opposite the first surface, and a fluid channel (110) located between the first surface and the second surface.