Radial Heat Exchanger and Diffuser Pipes for Lower Compressor Pressure Loss

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Solution Overview

Problem

Traditional environmental control systems in aircraft experience pressure losses and system inefficiencies due to ducting that restricts the flow path between components in compressor-heat exchanger assemblies.

Innovation Solution

An additively manufactured heat exchanger and diffuser pipe configuration that integrates the heat exchanger radially exterior to the impeller housing, with diffuser pipes connecting outlet ports of the impeller housing to inlet ports of the heat exchanger, featuring a spiral path and varying cross-sectional areas to minimize pressure loss and friction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If ducting is used to direct flow between components, then flow direction is controlled, but pressure losses and system inefficiencies increase

Engineering Contradiction:

Improveflow direction controlVSAvoidpressure loss

Core Design Contradiction:

Ease of operationVSLoss of energy

Solution Approach 1:

The patent merges the ducting function into the heat exchanger structure itself by integrating diffuser pipes directly with the heat exchanger cores. This eliminates separate ducting components and reduces the number of flow direction changes, thereby controlling flow direction while minimizing pressure losses through a more streamlined integrated design.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent transitions from traditional axial flow arrangement to a radial flow arrangement where the heat exchanger is positioned radially exterior to the impeller housing. This dimensional change allows the diffuser pipes to connect radially facing outlet ports directly to the heat exchanger inlet ports, reducing flow path restrictions and pressure losses while maintaining effective flow direction control.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Device complexity

If heat exchanger is positioned radially exterior to impeller housing, then packaging integration is enhanced, but manufacturing complexity increases

Engineering Contradiction:

Improvepackaging integrationVSAvoidmanufacturing complexity

Core Design Contradiction:

Device complexityVSEase of manufacture

Solution Approach 1:

The patent combines the heat exchanger and diffuser pipes into a single integrated assembly where the diffuser pipes are directly connected to the heat exchanger cores. This merging reduces the number of separate components and assembly steps, thereby enhancing packaging integration while actually simplifying manufacturing compared to traditional multi-component ducted systems.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent utilizes additive manufacturing technology to produce the integrated heat exchanger and diffuser pipe assembly. This manufacturing parameter change enables complex radial geometries and integrated structures that would be difficult to manufacture traditionally, thereby achieving enhanced packaging integration without proportionally increasing manufacturing complexity.

Inventive Principle:

Principle #35Parameter changes

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 reduces pressure loss, improves efficiency, and enhances packaging integration, offering higher stage efficiency, lower friction losses, and reduced manufacturing costs while maintaining performance at high inlet Mach numbers.

Implementation Method 1

diffuser pipes, wherein ones of the diffuser pipes connect ones of the inlet ports of the heat exchanger with ones of the outlet ports of the impeller housing

Methodology Applied

Scientific EffectDiffusion: Diffusion

Implementation Method 2

reduces pressure loss, improves efficiency

Methodology Applied

Scientific EffectPressure gradient: Pressure Gradient

Implementation Method 3

heat exchanger that is positioned radially exterior to the impeller housing and extends axially from an inlet end to an outlet end

Methodology Applied

Scientific EffectHeat exchanger: Heat Exchanger

Implementation Method 4

in operation an airflow moves along a first axial direction into the inlet end of the impeller housing and is compressed by the impeller

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentUS20260028126A1Additively manufactured heat exchanger and diffuser pipe coupled to a compressor stage

Publication Date: 2026.01.29 HAMILTON SUNDSTRAND CORP

AI summary

An aircraft system having an impeller housing, an impeller housed within the impeller housing, wherein the impeller housing extends from an inlet end and to an outlet end, wherein the outlet end defines circumferentially distributed radially facing outlet ports, wherein in operation an airflow moves along a first axial direction into the inlet end of the impeller housing and is compressed by the impeller; a heat exchanger that is positioned radially exterior to the impeller housing and extends axially from an inlet end to an outlet end, wherein the inlet end of the heat exchanger defines inlet ports, and wherein in operation airflow into the heat exchanger moves along a second axial direction that is opposite the first axial direction; and diffuser pipes, wherein ones of the diffuser pipes connect ones of the inlet ports of the heat exchanger with ones of the outlet ports of the impeller housing.