Multifurcating Heat Exchanger With Independent Flow Baffles
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Solution Overview
Problem
Heat exchangers face inefficiencies due to boundary layer formation, size constraints, and joint deterioration, which affect thermal resistance and structural integrity.
Innovation Solution
A heat exchanger design featuring a core with unit cells that form trifurcated passageways and independent baffles, allowing fluids to combine and divide efficiently, reducing thermal boundary layers and minimizing joints through additive manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If heat transfer fluids flow through the heat exchanger, then heat transfer occurs, but thermal boundary layer formation increases thermal resistance and reduces heat transfer efficiency
Solution Approach 1:
The patent employs flow disturbances and turbulence promoters within the passageways to mechanically disrupt the thermal boundary layer formation, preventing the stagnant fluid layers that create thermal resistance. This continuous disruption maintains higher heat transfer coefficients throughout operation.
Solution Approach 2:
The patent optimizes flow velocity, passageway geometry, and surface characteristics to change the flow regime and thermal boundary layer development parameters. By controlling Reynolds number and other dimensionless parameters, the system maximizes convective heat transfer while minimizing boundary layer resistance.
2Volume of moving object
If the heat exchanger size is reduced to meet system volume requirements, then space utilization improves, but heat transfer surface area and efficiency are compromised
Solution Approach 1:
The patent implements a multifurcating passageway system where multiple flow paths are nested within a compact core structure. The unit cells are arranged to maximize surface area density, with passageways branching and recombining to create extensive heat transfer surfaces within minimal envelope volume.
Solution Approach 2:
The patent transitions from two-dimensional planar heat exchanger surfaces to three-dimensional multifurcating passageway networks. This spatial arrangement allows heat transfer surfaces to extend in multiple directions simultaneously, dramatically increasing surface area within the same volume constraint.
3Ease of manufacture
If multiple joints such as brazed and welded joints are used to form the heat exchanger, then structural assembly is achieved, but joint deterioration over time decreases service life
Solution Approach 1:
The patent integrates multiple components into monolithic structures where possible, eliminating the need for separate joints. The core, passageways, and structural elements are formed as continuous integrated parts, removing the weak points that would otherwise require brazing or welding connections.
Solution Approach 2:
The patent employs seamless tubular or shell structures that provide structural integrity without requiring discrete joints. These continuous shell forms maintain strength and reliability while accommodating thermal expansion and pressure loads throughout the service life.
4Volume of moving object
If the heat exchanger is shaped to fit within specified system volume, then space utilization improves, but improper shaping results in ineffective space use and wasted volume
Solution Approach 1:
The patent divides the heat exchanger into modular unit cells that can be arranged in various configurations to match different system volume requirements. Each unit cell is a self-contained module with standardized interfaces, allowing flexible assembly into custom shapes without compromising internal flow patterns or heat transfer performance.
Solution Approach 2:
The patent designs universal unit cells that can serve multiple functions: structural support, flow distribution, and heat transfer. These multi-functional modules eliminate the need for separate structural and functional components, reducing overall volume while maintaining all required capabilities.
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
Enhances heat transfer efficiency, fits within specified system volumes, and maintains structural integrity by reducing thermal resistance and joint failures.
Implementation Method 1
heat transfer efficiency of the heat exchangers is determined, at least in part, by the flow of the heat transfer fluids through the heat exchangers
Implementation Method 2
As the heat transfer fluids flow through the heat exchangers, the heat transfer fluids tend to establish a boundary layer which increases thermal resistance
Implementation Method 3
the heat transfer fluids tend to establish a boundary layer which increases thermal resistance and reduces the heat transfer efficiency
Data Source
AI summary
A heat exchanger includes a core defining a first passageway for a first fluid flow and a second passageway for a second fluid flow. The core includes an assembly of a plurality of unit cells coupled together. Each unit cell defines a first passageway portion within an interior volume and a second passageway portion at an exterior surface. Each unit cell includes a plurality of first openings into the interior volume and forms the second passageway in volumes between the plurality of unit cells. The assembly is shaped to combine and divide the first fluid in the first passageway portion and combine and divide the second fluid in the second passageway portion during exchange of heat between the first fluid and the second fluid. Each second passageway portion receives the second fluid from three other second passageway portions. The heat exchanger further includes at least one baffle in at least one of the first passageway or the second passageway to route the first fluid flow independently from the second fluid flow.