Multimaterial Heat Exchanger With Progressive Divided Flow Circuit
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Solution Overview
Problem
Aircraft heat exchangers face challenges in optimizing heat transfer efficiency, fluid flow distribution, and pressure drop management, leading to increased weight, space consumption, and specific fuel consumption, particularly in severe-service conditions of aircraft engines.
Innovation Solution
A heat exchanger design with a unique internal fluid flow configuration that progressively divides and combines fluid streams, incorporating a multifunctional structure combining heat exchange and structural capabilities through the integration of materials with high thermal conductivity and strength, using advanced manufacturing techniques like brazing and diffusion bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional heat exchanger designs are used, then heat exchange function is provided, but weight increases and space is consumed
Solution Approach 1:
The patent combines the heat exchange function with the structural load-bearing function into a single integrated component. The heat exchanger is designed to serve dual purposes: cooling lubricant and supporting structural loads in the aircraft engine, thereby eliminating the need for separate structural components and reducing overall weight.
Solution Approach 2:
The heat exchanger is designed as a multifunctional component that performs both heat exchange and structural support functions. This universal design allows the same component to fulfill multiple roles in the aircraft engine system, reducing the total number of parts and associated weight.
2Reliability
If heat exchanger capacity is increased to meet severe-service conditions, then cooling performance improves, but device complexity and space requirements increase
Solution Approach 1:
The heat exchanger incorporates a divided flow circuit with multiple feed sections and discharge sections that progressively divide and combine fluid streams. This segmentation approach enhances heat transfer efficiency and flow distribution while maintaining a compact overall structure, avoiding the need for overly complex configurations.
Solution Approach 2:
The patent utilizes three-dimensional flow path arrangements and vertical integration of feed and discharge sections to achieve high cooling capacity within a compact footprint. By optimizing the spatial arrangement of fluid streams in multiple dimensions, the design meets severe-service cooling demands without excessive complexity.
3Temperature
If high thermal conductivity materials are used, then heat transfer efficiency improves, but structural strength decreases
Solution Approach 1:
The heat exchanger is constructed from materials that provide both high thermal conductivity for efficient heat transfer and sufficient structural strength to bear loads. The design may incorporate composite material structures or strategic material selection that balances thermal and mechanical properties to satisfy both heat exchange and structural requirements.
Solution Approach 2:
Different regions of the heat exchanger may utilize materials or structures optimized for their specific functions: high thermal conductivity materials in heat transfer zones and high-strength materials in load-bearing regions. This local optimization allows the component to achieve both efficient heat transfer and adequate structural strength.
4Productivity
If progressive divided flow circuit is implemented, then heat transfer efficiency improves, but manufacturing complexity increases
Solution Approach 1:
The divided flow circuit is segmented into standardized feed sections and discharge sections that can be manufactured using consistent processes. This modular segmentation approach simplifies manufacturing by repeating proven design units rather than creating entirely complex custom flow paths.
Solution Approach 2:
The flow circuit design incorporates preliminary considerations for manufacturing in the conceptual stage, selecting configurations that balance heat transfer performance with manufacturability. The progressive division and combination of streams is designed to accommodate standard fabrication techniques and assembly processes.
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 efficiency, reduced weight, and lower operational costs by optimizing fluid flow and structural integrity, addressing the challenges of conventional heat exchangers.
Implementation Method 1
a first section and a second section that are thermally connected to one another, the first section being configured to receive the fluid stream and provide a heat exchange relationship, the second section being configured to provide a heat exchange relationship
Implementation Method 2
an incoming fluid stream is progressively divided into multiple smaller streams, each of which delivers the heat exchange fluid into one or more heat exchange sections of the device
Implementation Method 3
using advanced manufacturing techniques like brazing and diffusion bonding
Implementation Method 4
using advanced manufacturing techniques like brazing and diffusion bonding
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
A multi-material heat exchanger, comprising one or more heat exchange sections formed from a first material, one or more structural sections formed from a second material, wherein the second material has a higher strength than the first material, wherein the one or more heat exchange sections and the one or more structural sections are coupled to one another to form a single integrated heat exchanger having functions of a structural component and a heat transfer device.