Wavy Heat Exchanger Core With Integrated Manifold Flow Balancing
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Solution Overview
Problem
Conventional heat exchanger assembly processes are costly and cumbersome, limiting the configuration and efficiency of thermal energy transfer due to complex component stacking and brazing, which restricts passage shape and orientation.
Innovation Solution
A heat exchanger design featuring non-linear fluid passages with varying lateral passages that increase in length and depth, defined by cutouts, allowing for efficient fluid distribution and thermal energy exchange, and formed using additive manufacturing processes to simplify assembly and enhance thermal efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional component stacking and brazing assembly processes are used, then heat exchangers can be manufactured, but the assembly becomes costly and cumbersome with limited configuration options
Solution Approach 1:
The patent merges multiple separate components (manifold and heat exchanger core) into a single integrated unit with fluid passages formed directly within the core structure. This eliminates the need for separate assembly operations and complex brazing processes, reducing manufacturing cost and complexity while enabling greater design flexibility for passage shapes and orientations.
Solution Approach 2:
The patent changes the manufacturing approach from conventional mechanical assembly to additive manufacturing, which allows for continuous variation of passage geometry parameters. This enables optimized sinusoidal and tortuous paths with variable cross-sections that cannot be achieved through traditional stacking and brazing methods.
2Reliability
If complex component assembly is used, then heat exchanger functionality is achieved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The manifold and heat exchanger core are merged into a single monolithic structure where fluid distribution channels are integrated directly with the heat transfer passages. This reduces the number of discrete components from multiple separate parts to a single manufactured unit, eliminating assembly steps while maintaining all necessary heat transfer functions.
Solution Approach 2:
The integrated core structure performs multiple functions simultaneously: it distributes fluid through manifold passages, directs flow through heat exchange passages, and provides structural support. This multi-functionality eliminates the need for separate manifold and core components, reducing device complexity while ensuring reliable heat transfer functionality.
3Ease of manufacture
If linear fluid passages are used, then manufacturing is simpler, but thermal energy transfer efficiency is reduced
Solution Approach 1:
The patent employs sinusoidal and tortuous curved paths for fluid passages instead of straight linear channels. These curved geometries increase the surface area available for heat transfer and enhance thermal mixing between fluids, significantly improving thermal energy transfer efficiency. The curved paths are formed directly in the additive manufacturing process, maintaining manufacturing simplicity while achieving superior thermal performance.
4Ease of manufacture
If uniform lateral passages are used, then manufacturing is easier, but fluid distribution efficiency decreases
Solution Approach 1:
The lateral passages are designed with varying lengths and geometries depending on their location within the core structure. Passages closer to the fluid inlet have different dimensions than those farther away, optimizing fluid distribution to achieve uniform flow rates across all heat exchange passages. This localized variation in passage geometry is seamlessly integrated into the additive manufacturing process, maintaining ease of manufacture while dramatically improving fluid distribution efficiency.
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 improves thermal energy transfer efficiency and reduces manufacturing complexity by enabling sinusoidal or tortuous fluid paths, increasing surface area and turbulence, while maintaining seamless fluid flow and minimizing pressure drop.
Implementation Method 1
a plurality of second fluid passages through which a second fluid is flowed from the second fluid inlet to the second fluid outlet to exchange thermal energy with the first fluid
Implementation Method 2
enabling sinusoidal or tortuous fluid paths, increasing surface area and turbulence
Data Source
AI summary
A heat exchanger includes a first fluid inlet, a first fluid outlet, a second fluid inlet, a second fluid outlet, and a core section. The core section includes a plurality of first fluid passages through which a first fluid is flowed, and a plurality of second fluid passages through which a second fluid is flowed to exchange thermal energy with the first fluid. The first fluid passages and the second fluid passages extend non-linearly along a length of the first fluid passages and the second fluid passages between a first core end and a second core end opposite the first core end. A manifold is operably connected to the plurality of first fluid passages. The manifold includes a plurality of lateral passages intersecting the plurality of first fluid passages. The plurality of lateral passages vary in length depending on distance from a fluidly upstream end of the core section.