Nested Manifold Heat Exchanger for Compact Fluid Routing
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Solution Overview
Problem
The challenge in designing a compact heat exchanger is to implement manifold portions that direct fluids between the heat exchanger core and interface portions while minimizing space constraints and maintaining efficient fluid flow, especially when the first and second fluid interface locations are fixed and the heat exchanger needs to fit within limited spaces, such as in automotive applications.
Innovation Solution
The design incorporates a first manifold portion with a tunnel extending through the second manifold portion at an angle, allowing the first fluid to flow through the tunnel and the second fluid to flow around it, which improves compactness and fluid flow properties by reducing vortices and providing additional heat exchange regions, and can be manufactured using additive manufacturing techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional manifold designs are used to direct fluids between heat exchanger core and interface portions, then fluid flow is maintained, but space constraints are not minimized and the heat exchanger size is increased
Solution Approach 1:
The first manifold portion is nested within the second manifold portion, with the first manifold extending through the second manifold like a tunnel. This nesting arrangement allows both manifolds to occupy the same spatial envelope, significantly reducing the overall heat exchanger volume while maintaining separate fluid flow paths for efficient heat exchange
Solution Approach 2:
The first manifold extends through the second manifold in a direction transverse to the second fluid flow direction, utilizing three-dimensional space efficiently. This dimensional arrangement allows compact integration of both manifolds without interfering with each other's fluid flow paths, solving the space constraint problem
2Volume of moving object
If compact manifold design is implemented to reduce heat exchanger size, then volume is reduced, but manufacturing complexity increases
Solution Approach 1:
The first and second manifold portions are combined into a single integrated manifold structure rather than separate components. This merging simplifies manufacturing by reducing assembly steps and enabling production as one piece, particularly suitable for additive manufacturing processes, while achieving the compact nested configuration
Solution Approach 2:
The invention employs additive manufacturing parameters and processes to create the complex nested manifold geometry that would be difficult to manufacture using traditional methods. By changing the manufacturing approach to accommodate the design, the patent achieves both compactness and manufacturability
3Adaptability or versatility
If fixed interface locations are used for first and second fluids, then system integration is simplified, but heat exchanger compactness is reduced
Solution Approach 1:
The manifold system is segmented into distinct first and second manifold portions with separate fluid flow paths. This segmentation allows each manifold to be optimized for its specific fluid while maintaining fixed interface locations, enabling system integration without compromising compactness through efficient spatial arrangement
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
This configuration enhances heat exchange efficiency, reduces the size of the heat exchanger core, and improves fluid flow distribution while fitting within constrained spaces, offering a more compact and efficient heat exchange solution.
Implementation Method 1
for exchange of heat between first fluid in the first fluid flow channels and second fluid in the second fluid flow channels
Implementation Method 2
reduces vortices and providing additional heat exchange regions
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A heat exchanger (4) comprises a heat exchanger core (20) comprising first fluid channels (22) and second fluid flow channels (24) for exchange of heat between the first and second fluids. First and second manifold portions (42, 44) are provided to guide the first and second fluids between the first and second fluid flow channels (22, 249 and first and second fluid interface portions (48, 49) which comprise fewer channels than the heat exchanger core (20). The first manifold portion (42) includes at least one tunnel portion (46) extending through the second manifold portion (44) at an angle to the direction of second fluid flow. Hence at least part of the first fluid is directed through the inside of the tunnel portion while the second fluid passes around the outside of the tunnel portion. This enables more compact heat exchanger design.