Segmented Conformal Heat Exchanger for Annular Layer Density
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Solution Overview
Problem
Conventional heat exchangers with non-conformal designs face limitations in performance due to their rectangular cross-section, which does not fit perfectly into curved annular passages, thereby restricting the number of layers and overall performance.
Innovation Solution
A conformal heat exchanger design is developed using a method that forms curved, annular plates with folded fins, allowing for increased layer density and improved curvature accommodation within annular passages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a non-conformal HX with rectangular cross-section is used, then the manufacturing is simpler, but the number of layers that can be included is limited and HX performance is limited
Solution Approach 1:
The patent applies curvature by forming the heat exchanger as an annular structure with curved fins and parting sheets that conform to the annular passage geometry. The fins are curved along their length to match the annular shape, allowing maximum utilization of the available flow domain and enabling increased layer density compared to rectangular designs.
2Productivity
If an annular conformal geometry HX is used, then additional layers can be fit into the HX improving performance, but the HX cannot be reliably manufactured
Solution Approach 1:
The patent applies segmentation by dividing the fin sheet into multiple discrete fins separated by gaps. This segmentation allows the fin sheet to be flexed and formed into the required annular curvature without excessive stress or distortion. The gaps act as stress relief zones that enable reliable manufacturing of the conformal geometry.
Solution Approach 2:
The patent applies local quality by positioning gaps at specific locations between fins where curvature accommodation is needed. The gaps are strategically placed to allow local flexibility in regions requiring curvature adaptation, while maintaining structural integrity in other regions. This localized modification enables conformal geometry without compromising overall manufacturability.
3Device complexity
If a non-conformal HX design is used, then the structure is simpler, but inert blockages are created instead of active heat transfer elements
Solution Approach 1:
The patent applies curvature to eliminate inert blockages by designing fins and parting sheets that conform to the annular passage geometry. This allows the heat exchanger to fully utilize the available flow domain, converting what would be wasted space in rectangular designs into active heat transfer surfaces. The curved configuration ensures continuous contact between heat transfer elements and the flow path.
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 conformal heat exchanger design enhances performance by increasing the number of active heat transfer layers, achieving lighter weight, lower pressure drop, and improved heat load capacity compared to non-conformal designs.
Implementation Method 1
a fin sheet interposed between the parting sheets and corrugated along a first axis to form fins. Each of the fins is segmented to define gaps, which are arranged along a second axis perpendicular to the first axis, and which cooperatively accommodate curvatures of the parting sheets and the fin sheet in a third axis perpendicular to the first and second axes.
Implementation Method 2
The base portions and the connecting portion are bonded to corresponding ones of the parting sheets... braze bonds between base portions of the fins and a corresponding one of the parting sheets are substantially continuous and braze bonds between a connecting portion of the fins and a corresponding one of the parting sheets are segmented at each gap.
Data Source
AI summary
A heat exchanger includes parting sheets and a fin sheet interposed between the parting sheets and corrugated along a first axis to form fins. Each of the fins is segmented to define gaps, which are arranged along a second axis perpendicular to the first axis, and which cooperatively accommodate curvatures of the parting sheets and the fin sheet in a third axis perpendicular to the first and second axes.