Two-Pass Heat Exchanger Turnaround With Arcuate Channels
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Solution Overview
Problem
Conventional turnaround sections in two-pass crossflow heat exchangers using additive manufacturing (AM) face challenges such as thermal inefficiency, fluid mixing and distribution issues, and manufacturing difficulties, particularly in the turnaround tank design, which reduces heat exchange efficiency and disrupts fluid flow.
Innovation Solution
A turnaround section with arcuate housing and radially spaced arcuate fluid flow channels, featuring separators between adjacent channels, allows for direct fluid flow between main and return channels, enhancing heat exchange and improving fluid distribution, and is easily manufactured using AM.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional turnaround tank design is used to receive fluid from all channels, then the fluid can be turned around to flow back through the second pass section, but no heat exchange occurs in the turnaround section and the large voids required are difficult to manufacture using additive manufacturing
Solution Approach 1:
The patent merges the turnaround function with heat exchange functionality by integrating heat exchange channels directly into the turnaround section structure. The turnaround section contains multiple channels that guide fluid flow while simultaneously enabling heat transfer between hot and cold fluid streams, eliminating the need for separate heat exchange components and large void spaces.
Solution Approach 2:
The patent transitions from a two-dimensional planar heat exchange surface to a three-dimensional multi-channel structure within the turnaround section. By creating channels that extend in multiple directions and layers, the design achieves both fluid redirection and heat exchange functions within a compact volumetric space that is well-suited for additive manufacturing.
2Ease of operation
If a conventional turnaround tank design is used, then the fluid can be turned around, but the fluid distribution in the main core section is disturbed due to the turnaround section design
Solution Approach 1:
The turnaround section is segmented into multiple independent channels, each handling fluid from specific heat exchange channels. This segmentation allows for controlled and uniform fluid distribution as each channel independently manages its fluid stream, preventing the mixing and distribution disturbances that occur in conventional single-void turnaround tanks.
3Ease of manufacture
If additive manufacturing is used to create custom shaped heat exchanger channels, then new channel shapes can be created to address boundary layer resistance, but conventional turnaround tank designs are difficult to manufacture using 3D printing
Solution Approach 1:
The patent combines the turnaround tank structure with heat exchange channels into a single integrated component that can be manufactured as one piece using additive manufacturing. This eliminates the need for separate turnaround tanks and allows the complex multi-channel geometry to be directly printed, achieving both manufacturing ease and design flexibility.
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 improves thermal efficiency and fluid distribution, reduces waste, and facilitates easy manufacturing, resulting in a more efficient and cost-effective heat exchanger.
Implementation Method 1
a turnaround section for use with a two-pass crossflow heat exchanger... each arcuate channel having a first end configured, in use, to receive a first fluid from flow channels of a heat exchanger core and a second end to return the first fluid to return channels of the core
Implementation Method 2
Heat exchangers typically work by the transfer of heat between fluid flowing in parallel channels defined by metal plates of a heat exchanger core... heat is exchanged across the boundary between the channels
Implementation Method 3
Thermal properties are improved by the introduction of turbulence in the flow channels and so, conventionally, a heat exchanger core comprises corrugated metal plates arranged adjacent each other so as to define corrugated flow channels for the heat exchange fluids
Implementation Method 4
In conventional heat exchanger channels, the viscous fluids that are commonly used create a thick boundary layer at the walls of the channels. This boundary layer presents a resistance to heat exchange across the channel walls and reduces the amount of energy that can be transferred through the channel wall by heat exchange
Data Source
Figure 1
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Figure 4~5
AI summary
A turnaround section for use with a two-pass crossflow heat exchanger, the turnaround section comprising an arcuate housing (200) and a plurality of arcuate fluid flow channels (30) radially spaced within the housing, each arcuate channel having a first end (32) configured, in use, to receive a first fluid from flow channels of a heat exchanger core and a second end (34) to return the first fluid to return channels of the core, and wherein a plurality of separators (40) are provided between each adjacent pair of arcuate channels to form further channels (25) between the arcuate channels that extend and provide for flow of a second fluid in a plane transverse to the plane of the arcuate channels.