Morphing Cross Section Heat Exchanger for Multi-Pass Flow
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Solution Overview
Problem
Existing heat exchangers, particularly diamond channel types, are limited by structural and interface restrictions, preventing effective use of cross flow and often allowing only single pass flow, which limits heat transfer efficiency and space optimization in aircraft structures.
Innovation Solution
A multilayer heat exchanger design with morphing sections that transition between rectangular and diamond cross sections, enabling multiple pass flow and efficient heat transfer without increasing volume, allowing for both parallel and counter flow configurations and accommodating different mounting requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If diamond channel heat exchangers are used to improve heat transfer efficiency, then heat transfer performance is improved, but structural and interface restrictions prevent effective use of cross flow and multi-pass configurations
Solution Approach 1:
The heat exchanger is divided into multiple independent layers, each capable of handling different flow configurations. This segmentation allows the system to achieve both high heat transfer efficiency through diamond channels in some layers and flow flexibility through rectangular channels in other layers, resolving the contradiction between productivity and adaptability.
Solution Approach 2:
The patent employs a composite structure combining different channel geometries (diamond and rectangular) within the same heat exchanger system. This composite approach allows optimization of heat transfer efficiency in diamond channel layers while maintaining flow configuration flexibility in rectangular channel layers, effectively resolving the technical contradiction.
2Productivity
If single pass flow is used in diamond channel heat exchangers, then structural simplicity is maintained, but heat transfer efficiency is limited due to reduced contact time between hot and cold flows
Solution Approach 1:
By segmenting the heat exchanger into multiple layers with different flow configurations, the system can implement multi-pass flow in certain layers to increase contact time and heat transfer efficiency, while maintaining overall structural simplicity through the modular layer design.
Solution Approach 2:
The patent transitions from single-pass two-dimensional flow to multi-pass three-dimensional flow by stacking multiple layers with alternating flow directions. This dimensional change allows increased contact time between hot and cold flows without significantly increasing the footprint, resolving the contradiction between productivity and device complexity.
3Productivity
If the heat exchanger volume is increased to provide more heat transfer surface area, then heat transfer efficiency is improved, but available space in aircraft structures is consumed
Solution Approach 1:
The heat exchanger layers are stacked in a nested configuration where multiple flow paths are contained within a compact vertical arrangement. This nesting allows maximum heat transfer surface area to be packed into minimum volume, resolving the contradiction between productivity and volume by utilizing vertical space efficiently.
Solution Approach 2:
The patent utilizes the vertical dimension by stacking multiple layers to increase heat transfer surface area without expanding the horizontal footprint. This dimensional approach allows high heat transfer efficiency while maintaining compact volume suitable for aircraft structures, effectively resolving the technical contradiction.
4Ease of operation
If inlet and outlet connections are arranged on opposite sides for single pass flow, then flow path simplicity is maintained, but system integration with other aircraft components becomes more difficult
Solution Approach 1:
By segmenting the flow paths into multiple passes within stacked layers, the heat exchanger can provide multiple inlet and outlet options on the same side or opposite sides, facilitating easier system integration with aircraft components while managing flow path complexity through modular layer design.
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 enhances heat transfer efficiency by utilizing all internal surfaces as primary heat transfer areas, allowing for scalable and compact heat exchanger configurations that can fit within constrained aircraft spaces while maintaining fluid pressure and flow characteristics.
Implementation Method 1
in the first and second morphing sections the cross section of the flow paths morphs between first cross section and the second cross section
Implementation Method 2
heat exchangers for transfer of heat between different fluids are very widely used and exist in various forms. Typically heat exchangers are arranged for flow of a primary fluid and a secondary fluid with heat being transferred between the two fluids
Implementation Method 3
Diamond channel heat exchangers provide improved performance compared to convention plate fin heat exchanger because with the use of diamond channels all of the internal core faces act as primary heat transfer surfaces
Data Source
AI summary
A layer of a heat exchanger includes plurality of flow paths, a first end section comprising a plurality of flow path inlets and a plurality flow path outlets. a second end section comprising a turnaround section, a first morphing section fluidly connect to the first end section, a second morphing section fluidly connected to the second end section; and a central section positioned between and fluidly connected to the first and second morphing sections. The plurality of flow paths extend from the flow path inlets to the flow path outlets via the turnaround section in the second end section. In the first end section and the second end section the flow paths have a first cross section. The central section the flow paths have a second cross section and in the first and second morphing section the cross section of the flow paths morph between first and second cross sections.