Nonrectangular Heat Exchanger Core for Aerospace Thermal Management
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Solution Overview
Problem
Conventional heat exchangers with rectangular cross-sectional areas are not optimal for aerospace applications, as they do not provide a compact, low-weight, and efficient means of heat transfer, leading to inefficiencies in thermal energy exchange and increased thermal stresses.
Innovation Solution
A heat exchanger with a nonrectangular cross-sectional area, featuring a plurality of cold flow layers and hot flow tubes arranged in a circular, hexagonal, or octagonal configuration, which reduces thermal stresses and ensures equal flow resistance and pressure drop across the entire cross-sectional area, accommodating high fluid pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a rectangular cross-sectional area is used for the heat exchanger core, then the tube geometry and spacing can be kept constant across the core, but the heat exchanger does not provide a compact, low-weight, and efficient means of heat transfer
Solution Approach 1:
The patent applies spheroidality by transitioning from a rectangular cross-section to a circular cross-section for the heat exchanger core. This curvature change enables more efficient heat transfer and a more compact design while maintaining structural integrity. The circular geometry allows for optimized tube spacing and arrangement that improves thermal performance compared to rectangular configurations.
2Ease of manufacture
If a rectangular cross-sectional area is used for the heat exchanger core, then the structure is simple to manufacture, but it leads to inefficiencies in thermal energy exchange and increased thermal stresses
Solution Approach 1:
The patent changes the geometric parameter of the cross-section from rectangular to circular, which fundamentally alters the stress distribution characteristics. The circular geometry provides more uniform stress distribution under thermal and pressure loads, reducing peak thermal stresses and improving reliability. This parameter change also optimizes the surface-area-to-volume ratio for enhanced heat transfer efficiency.
3Adaptability or versatility
If a rectangular cross-sectional area is used for the heat exchanger core, then the design is conventional and easy to implement, but it does not accommodate high fluid pressures efficiently
Solution Approach 1:
The circular cross-section provides superior pressure accommodation compared to rectangular geometries. The curved surfaces distribute internal fluid pressures more evenly across the structure, eliminating stress concentration at corners that plagues rectangular designs. This makes the heat exchanger better suited for high-pressure aerospace applications while maintaining a compact form factor.
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 nonrectangular heat exchanger design enhances thermal energy transfer efficiency, maintains consistent performance across the entire cross-sectional area, and accommodates high fluid pressures, making it suitable for aerospace applications.
Implementation Method 1
heat exchanger extending axially along centerline C and configured to allow thermal energy transfer between first fluid 12 and second fluid 14
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
A heat exchanger (10) includes a core (15) having a nonrectangular cross-sectional area, a plurality of cold flow layers (18) centered about a centerline with each of the plurality of cold flow layers (34) separated by corresponding walls. The heat exchanger (10) also includes a plurality of hot flow tubes (34) corresponding to each of the plurality of cold flow layers.