Triangular Flow Passage Heat Exchanger for High HTC and Low Weight
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Solution Overview
Problem
Conventional heat exchangers face challenges in achieving a balance between high heat transfer coefficient (HTC) and surface area, particularly in compact and lightweight designs, especially for high-temperature and high-pressure applications where thick walls are undesirable.
Innovation Solution
A heat exchanger design featuring upper and lower walls with turbulators and a fin pack forming triangular flow passages, along with side walls, which includes chevron or broken-V turbulators oriented along the centerline, providing a high HTC while maintaining structural rigidity and minimizing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional rectangular flow passages with smooth side walls are used, then a high heat transfer coefficient is achieved, but the surface area is low
Solution Approach 1:
The flow passage is segmented into multiple triangular sections by adding transverse partitions (fins) that divide the rectangular passage into smaller triangular flow passages. This segmentation increases the effective heat transfer surface area while maintaining the high HTC characteristics of turbulent flow through the turbulators.
Solution Approach 2:
The design transitions from a two-dimensional rectangular flow passage to a three-dimensional triangular flow passage configuration with added depth through the fin structure. This dimensional change allows simultaneous achievement of high HTC (through turbulence) and high surface area (through the fin extensions).
2Area of stationary object
If plate-fin heat exchanger design with thin fins is used, then high surface area is achieved, but the heat transfer coefficient is low
Solution Approach 1:
The design merges the advantages of both conventional passages (high HTC through turbulence) and plate-fin structures (high surface area) by combining turbulators with a fin pack system. The turbulators generate turbulence for high HTC while the fins provide extended surface area, achieving both goals simultaneously.
3Strength
If thick walls are used for high temperature and pressure heat exchangers, then structural strength is improved, but the heat exchanger becomes heavier and bulkier
Solution Approach 1:
Instead of uniformly thick walls throughout the structure, the design uses localized thickening only where structurally necessary (at bonding surfaces and critical load-bearing areas) while maintaining thin walls in the flow passages. This localized approach provides sufficient strength for high temperature and pressure applications while minimizing overall weight and bulk.
Solution Approach 2:
The triangular flow passage configuration allows for more efficient structural distribution, enabling thin-walled construction that maintains strength through geometric stability rather than relying on wall thickness. The triangular geometry provides inherent structural rigidity with minimal material.
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 enhances heat transfer efficiency with minimal pressure drop, achieving high HTC across the surface area while maintaining a compact and lightweight structure, suitable for industrial and aviation applications.
Implementation Method 1
The parting surfaces of such heat exchangers can be provided with flow turbulators that can be configured to generate a vortex flow
Implementation Method 2
a fin pack between the upper and lower surfaces, the fin pack comprising alternating angled walls extending between the upper and lower surfaces to define triangular flow passages
Data Source
AI summary
A heat exchanger element has upper and lower walls defining upper and lower flow surfaces of a flow path; turbulators on the upper and lower flow surfaces; and a fin pack between the upper and lower surfaces, the fin pack having alternating angled walls extending between the upper and lower surfaces to define triangular flow passages in the flow path between the upper and lower walls. A heat exchanger stack can have multiple layers of the heat exchanger element, and a method for making the heat exchanger is disclosed. The structure produces advantageous flow characteristics.