Microchannel Heat Exchanger Volume Reduction via Planar Segmentation
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Solution Overview
Problem
Current heat exchangers for turbine engines are large, expensive, and inefficient for heating compressed gases, particularly when using solar power, due to their tortuous paths and lack of compact design.
Innovation Solution
A microchannel-based heat exchanger system with a first flow panel and second flow panel, where the first surface defines a set of microchannels for gas flow and the second surface defines another set, coupled with covers to form boundaries, creating a heat transfer passageway for a heat transfer medium to flow in an opposite direction, enhancing heat transfer efficiency through counter-flow and cross-flow configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional shell and tube heat exchangers are used for heating compressed gases in turbine engines, then heat transfer function is provided, but the device occupies very large volume and high cost
Solution Approach 1:
The patent transitions from traditional three-dimensional shell and tube heat exchanger geometry to a planar microchannel plate heat exchanger design. By flattening the heat transfer surfaces into parallel plates with microchannels, the device achieves dramatically reduced volume (90% reduction) while maintaining effective heat transfer area through the stacked plate configuration.
Solution Approach 2:
The heat exchanger is divided into multiple discrete plate elements, each containing microchannels on both surfaces. These plates are stacked and sealed together to form the complete heat exchanger assembly. This segmentation allows for compact arrangement and efficient heat transfer while reducing overall device volume.
2Productivity
If traditional heat exchangers with tortuous paths are used, then heat transfer medium can be conveyed, but the path is inefficient for solar power heating applications
Solution Approach 1:
The patent simplifies the flow path by transitioning from tortuous three-dimensional tube routes to straight-line microchannels within planar plates. The microchannels provide direct, linear flow paths that eliminate unnecessary bends and turns, improving flow efficiency and reducing pressure losses for solar heating applications.
Solution Approach 2:
The patent changes the flow path geometry parameters from large-diameter curved tubes to small-diameter straight microchannels. This parameter change reduces flow path length, eliminates tortuosity, and improves heat transfer efficiency while maintaining compact device dimensions.
3Volume of moving object
If microchannel-based heat exchanger is used to reduce volume, then compact design is achieved, but manufacturing complexity increases
Solution Approach 1:
The heat exchanger is constructed from multiple identical or similar plate elements that can be manufactured using the same processes. Each plate contains microchannels formed by identical patterning and sealing operations. This modular segmentation allows for standardized manufacturing, reducing overall manufacturing complexity despite the advanced microchannel technology.
Solution Approach 2:
The plate design serves multiple functions simultaneously: it provides structural support, contains the microchannels for fluid flow, and acts as a heat transfer surface. The covers seal the microchannels while also providing mounting surfaces for connections. This multi-functionality reduces the number of separate components needed, simplifying assembly and manufacturing.
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 microchannel-based heat exchanger provides improved heat transfer efficiency and a compact design, reducing volume by approximately 90% compared to traditional shell and tube heat exchangers, while maintaining thermal efficiency and minimizing pressure loss, thus offering a cost-effective solution for heating compressed gases in turbine engines.
Implementation Method 1
the first flow panel coupled to a second flow panel to define a first heat transfer passageway between the first cover of the first flow panel and a cover of the second flow panel, within which a heat transfer medium can be conveyed in a second direction, the second direction opposite the first direction
Data Source
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AI summary
An apparatus includes a first flow panel and a second flow panel. The first flow panel includes a first flow portion and a second flow portion. The first flow portion defines a flow passageway within which a gas can flow in a first direction. The second flow portion defines a set of microchannels in fluid communication with the flow passageway and within which the gas can flow in a second direction, where the second direction is nonparallel to the first direction. The first flow panel is coupled to the second flow panel to define a heat transfer passageway within which a heat transfer medium can be conveyed in a third direction, where the third direction is opposite the first direction. In such embodiments, the heat transfer passageway is fluidically isolated from the flow passageway and the set of microchannels by a thermally conductive side wall.