Variable Cross-Section Heat Exchanger Headers

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Solution Overview

Problem

Conventional heat exchanger headers face limitations in performance due to design constraints, size, weight, structural reliability, and inability to handle high temperatures, which restricts heat transfer efficiency and system integration.

Innovation Solution

A heat exchanger header design featuring first and second flow channels with a lobe section having a non-uniform cross-sectional area that changes along the flow direction, expanding from a fluid circuit opening to a maximum area and then reducing to a uniform section, optimizing flow area distribution and reducing pressure drops.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional plate fin construction is used, then structural simplicity is maintained, but heat transfer performance is limited and size/weight cannot be reduced

Engineering Contradiction:

Improveheat transfer performanceVSAvoiddesign constraints

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The header is divided into multiple flow channels (first flow channels for hot fluid, second flow channels for cold fluid) with distinct configurations. Each channel type has optimized geometry for its specific function, allowing independent optimization of heat transfer performance without compromising structural integrity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different sections of the flow channels have different cross-sectional area profiles. The lobe section has a non-uniform cross-sectional area that varies along the flow direction, creating localized flow acceleration and enhancement of heat transfer coefficients in specific regions where it is most needed

Inventive Principle:

Principle #3Local quality

2Loss of energy

If traditional header design is used, then manufacturing simplicity is maintained, but pressure loss is high and flow distribution is poor

Engineering Contradiction:

Improvepressure lossVSAvoidheader design

Core Design Contradiction:

Loss of energyVSEase of manufacture

Solution Approach 1:

The cross-sectional area of the flow channels is made variable rather than constant. The lobe section features a non-uniform cross-sectional area that changes along the flow direction, dynamically adapting the flow path geometry to optimize velocity distribution and minimize pressure losses while maintaining effective flow distribution to the core

Inventive Principle:

Principle #15Dynamics

3Temperature

If conventional heat exchanger design is used, then size is reduced, but temperature handling capability is limited

Engineering Contradiction:

Improvetemperature handling capabilityVSAvoidheat exchanger size

Core Design Contradiction:

TemperatureVSVolume of stationary object

Solution Approach 1:

The header is formed from a material or composite structure capable of withstanding high temperatures while maintaining structural integrity. The design integrates high-temperature resistant properties into the header construction, enabling the heat exchanger to handle elevated temperatures without requiring larger dimensions for thermal management

Inventive Principle:

Principle #40Composite materials

4Productivity

If uniform cross-sectional area channels are used, then manufacturing simplicity is maintained, but heat transfer efficiency is reduced

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidchannel geometry

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The cross-sectional area parameter of the flow channels is varied along the flow direction in the lobe section. This parameter change creates non-uniform velocity distribution and enhances turbulent mixing, thereby improving heat transfer efficiency without requiring complete redesign of the entire channel geometry

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 design enhances heat transfer performance, reduces pressure loss, and allows for more compact and integrated systems capable of handling higher temperatures, improving overall efficiency and integration opportunities.

Implementation Method 1

a lobe section defining a non-uniform cross-sectional flow area that changes along a flow direction... The non-uniform cross-sectional area can change non-linearly... expands in flow area from the fluid circuit opening to a maximum flow area, wherein the lobe section then can reduce in flow area from the maximum flow area to the uniform section flow area

Methodology Applied

Scientific EffectPressure gradient: Pressure Gradient

Data Source

PatentEP3348948B1Variable headers for heat exchangers

Publication Date: 2020.11.18 HAMILTON SUNDSTRAND CORP

Figure 1A~1B
Figure 1C~1D
Figure 1E

AI summary

A heat exchanger header includes a plurality of first flow channels (103) and second flow channels (105), each flow channel including a fluid circuit opening (106, 107) for fluid communication with a fluid circuit of a heat source and a core opening (109) for communication with a heat exchanger core (111), wherein at least the first flow channels include a lobe section (113) defining a non-uniform cross-sectional flow area that changes along a flow direction.