Radial Heat Exchanger Core With Expanding Flow Channels
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Solution Overview
Problem
Traditional manufacturing methods for heat exchangers impose limitations on geometry, shape, and arrangement of internal features, constraining thermal energy transfer and fluid flow performance, and diminish the ability to handle high pressures and temperatures along with their associated transient conditions.
Innovation Solution
An additively manufactured heat exchanger with a radial configuration and central spar design, featuring integrally formed components such as mounting arms and a curved exterior, allows for increased thermal energy transfer and pressure drop efficiency while accommodating thermal expansion and vibrational loads through compliant connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional manufacturing methods are used for heat exchangers, then manufacturing simplicity is maintained, but geometry, shape, and arrangement of internal features are constrained
Solution Approach 1:
The patent employs additive manufacturing technology to fundamentally change the manufacturing process parameters, enabling the creation of complex three-dimensional geometries, curved surfaces, and optimized internal flow channels that cannot be achieved with traditional manufacturing methods. This parameter change in the manufacturing process directly resolves the contradiction by prioritizing geometric freedom over manufacturing simplicity.
2Use of energy by moving object
If traditional manufacturing methods are used, then manufacturing simplicity is maintained, but thermal energy transfer and fluid flow performance are constrained
Solution Approach 1:
The patent utilizes curved exterior surfaces and optimized flow channel geometries enabled by additive manufacturing to enhance thermal energy transfer efficiency. The curved designs allow for better fluid distribution and increased surface area contact, directly improving thermal performance while accepting the inherent manufacturing complexity of additive processes.
3Reliability
If traditional manufacturing methods are used, then manufacturing simplicity is maintained, but ability to handle high pressures and temperatures is diminished
Solution Approach 1:
The patent integrates multiple components including the heat exchanger core, mounting arms, and compliant connections into a single additively manufactured structure. This merging eliminates weak points from traditional multi-component assemblies, enhancing the overall ability to withstand high pressures and temperatures while accepting the complexity of manufacturing such an integrated structure through additive processes.
4Stability of the object's composition
If rigid connections are used at connection points, then structural stability is maintained, but stress and strain during thermal expansion are increased
Solution Approach 1:
The patent incorporates compliant connections with flexible geometries at the mounting arms and connection points. These flexible structures allow for thermal expansion and contraction while maintaining structural stability, reducing stress and strain concentrations that would occur with rigid connections. The compliant design accepts manufacturing complexity to achieve superior structural performance under thermal loads.
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 enhances thermal energy transfer and pressure drop efficiency, reduces stress and strain at connection points, and improves the heat exchanger's ability to handle high pressures and temperatures by allowing for thermal expansion and contraction.
Implementation Method 1
a second fluid circuit acting as a conduit for transporting a second fluid therethrough to facilitate transfer of thermal energy between the second fluid and one or more other fluids passing through
Implementation Method 2
allowing for thermal expansion and contraction
Data Source
Figure 1
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AI summary
A heat exchanger includes a first set of fins (82), a second set of fins (90), and an exterior wall. The first set of fins extend radially and are coaxial with each other. The first set of fins forms a first set of channels. The second set of fins extend radially and are coaxial with each other. The second set of fins forms a second set of channels. Channels (118) of the first and second sets of channels are disposed in an alternating pattern in a circumferential direction of the heat exchanger. The first and second sets of fins are integrally formed together. A cross-sectional width of a channel of at least one of the first set of channels and the second set of channels increases as a radial distance from a centerline axis of the heat exchanger increases.