Progressive Divided-Flow Heat Exchanger for Compact Structural Packaging
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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 applications like aerospace 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 methods like brazing and additive manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If heat exchanger size is reduced to save weight and space, then weight and space consumption decrease, but heat transfer efficiency deteriorates
Solution Approach 1:
The heat exchanger is divided into multiple heat exchange sections with progressively smaller cross-sectional areas in the flow direction. This segmentation allows the device to maintain effective heat transfer surface area while reducing overall volume and weight, as each section is optimized for its specific flow rate and heat transfer requirements.
Solution Approach 2:
The patent transitions from a conventional uniform cross-section design to a variable cross-section design where the cross-sectional area changes in the flow direction. This dimensional variation enables compact packaging of heat exchange surfaces while maintaining adequate heat transfer efficiency throughout the device.
2Volume of stationary object
If heat exchanger size is reduced to save space, then space consumption decreases, but pressure drop management deteriorates
Solution Approach 1:
By segmenting the heat exchanger into multiple sections with progressively smaller cross-sectional areas, the patent distributes the pressure drop across several stages rather than concentrating it in a single compact section. This gradual transition helps manage pressure drop more effectively while maintaining compact overall dimensions.
Solution Approach 2:
The patent changes the geometric parameters of the heat exchanger channels along the flow direction, specifically reducing cross-sectional area progressively. This parameter variation optimizes the balance between compact volume and acceptable pressure drop by adapting the flow area to the local heat transfer and pressure requirements.
3Ease of manufacture
If conventional heat exchanger designs are used, then manufacturing is simpler, but heat transfer efficiency and flow distribution are suboptimal
Solution Approach 1:
The patent employs parameter changes by varying the cross-sectional area of heat exchange channels along the flow direction. This creates a progressive divided flow circuit that optimizes heat transfer efficiency and flow distribution while remaining manufacturable through established 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 a more compact, lightweight, and cost-effective heat exchanger that optimizes heat transfer efficiency, reduces space, and minimizes specific fuel consumption.
Implementation Method 1
a heat exchange fluid circuit including a plurality of heat exchange fluid passages that are configured to provide a heat exchange relationship for the heat exchanger
Data Source
AI summary
A heat exchanger including a fluid circuit in which 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; and/or in which multiple fluid streams of the fluid circuit are discharged from one or more heat exchanger sections, each of which are progressively combined into one or more larger streams before exiting the device. The heat exchanger may have a thin body portion and a thick body portion and may adapt a depth of the fluid circuit to the changes in thickness of the heat exchanger body. The heat exchanger may form a structural component and may integrate multiple materials to provide both heat exchange and structural functionality into a single device. Other structural fluid transfer devices having fluid flow and structural functionality also are provided.