U.S. patent application number 15/914042 was filed with the patent office on 2019-09-12 for high temperature plate fin heat exchanger.
The applicant listed for this patent is United Technologies Corporation. Invention is credited to Alexander Broulidakis, Adam J. Diener, Michael A. Disori, David J. Hyland, William P. Stillman, Jeremy Styborski.
Application Number | 20190277579 15/914042 |
Document ID | / |
Family ID | 65724243 |
Filed Date | 2019-09-12 |
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United States Patent
Application |
20190277579 |
Kind Code |
A1 |
Disori; Michael A. ; et
al. |
September 12, 2019 |
HIGH TEMPERATURE PLATE FIN HEAT EXCHANGER
Abstract
A heat exchanger includes a plate portion including a top
surface, bottom surface, a leading edge, a trailing edge and a
plurality of internal passages extending between an inlet and an
outlet. A fin portion extends outward from one of the top surface
and the bottom surface. The fin portion and the leading edge of the
plate portion define a leading edge contour. A cast plate for a
heat exchanger and a method are also disclosed.
Inventors: |
Disori; Michael A.;
(Glastonbury, CT) ; Stillman; William P.;
(Sturbridge, MA) ; Diener; Adam J.; (Marlborough,
CT) ; Broulidakis; Alexander; (Tolland, CT) ;
Hyland; David J.; (Portland, CT) ; Styborski;
Jeremy; (Manchester, CT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
United Technologies Corporation |
Farmington |
CT |
US |
|
|
Family ID: |
65724243 |
Appl. No.: |
15/914042 |
Filed: |
March 7, 2018 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F28D 1/05383 20130101;
F28F 3/025 20130101; F28F 1/26 20130101; F28F 1/022 20130101; F28F
2210/10 20130101; F28F 2215/06 20130101 |
International
Class: |
F28F 3/02 20060101
F28F003/02 |
Claims
1. A heat exchanger comprising: a plate portion including a top
surface, bottom surface, a leading edge forming a continuous
curvilinear surface between the top surface and the bottom surface,
a trailing edge and a plurality of internal passages extending
between an inlet and an outlet, the continuous curvilinear surface
extending along a width of the plate portion transverse to the
plurality of internal passages; a fin portion extending outward
from one of the top surface and the bottom surface, wherein the fin
portion includes a leading edge that merges into the continuous
curvilinear surface formed by the leading edge of the plate portion
to define a continuous curvilinear leading edge contour.
2. The heat exchanger as recited in claim 1, wherein the fin
portion and trailing edge of the plate portion define a trailing
edge contour.
3. The heat exchanger as recited in claim 2, wherein the leading
edge contour and the trailing edge contour are disposed within a
plane transverse to the plurality of internal passages.
4. The heat exchanger as recited in claim 1, wherein the plurality
of internal passages comprise one of an elliptical shape and a
rectilinear shape in cross-section.
5. The heat exchanger as recited in claim 1, wherein the fin
portion includes a fin thickness in cross-section that varies
between the leading edge and the trailing edge.
6. The heat exchanger as recited in claim 5, wherein the fin
thickness is largest at the leading edge.
7. The heat exchanger as recited in claim 1, wherein the fin
portion comprises a plurality of bottom fin portions extending
outward from the bottom surface and a plurality of top fin portions
extending outward from the top surface, wherein each of the
plurality of top fin portions are offset from the plurality of
bottom fin portions.
8. The heat exchanger as recited in claim 1, including an inlet
manifold in fluid communication with the inlet and an outlet
manifold in fluid communication with the outlet.
9. The heat exchanger as recited in claim 1, wherein the plate
portion and the fin portion comprise a single unitary cast
item.
10. A cast plate for a heat exchanger comprising: a plate portion
including a top surface, bottom surface, a curvilinear leading
edge, a trailing edge and a plurality of internal passages
extending between an inlet and an outlet; and a plurality of bottom
fin portions extending outward from the bottom surface and a
plurality of top fin portions extending outward from the top
surface, wherein each of the plurality of top fin portions are
offset from the plurality of bottom fin portions, wherein at least
one of the plurality of top fin portions and the bottom fin
portions merge with the curvilinear leading edge to define a
continuous curvilinear leading edge contour of the plate
portion.
11. The cast plate as recited in claim 10, wherein at least one of
the plurality of top fin portions and the bottom fin portions
define a continuous curvilinear trailing edge contour common with
the trailing edge of the plate portion.
12. The cast plate as recited in claim 11, wherein the leading edge
contour and the trailing edge contour are disposed within
respective planes transverse to the plurality of internal
passages.
13. The heat exchanger as recited in claim 12, wherein the
plurality of internal passages comprise one of an elliptical shape
and a rectilinear shape in cross-section.
14. The heat exchanger as recited in claim 10, wherein each of the
plurality of top fin portions and bottom fin portions includes a
fin thickness that is largest at the leading edge.
15-18. (canceled)
Description
BACKGROUND
[0001] A plate fin heat exchanger includes adjacent flow paths that
transfer heat from a hot flow to a cooling flow. The flow paths are
defined by a combination of plates and fins that are arranged to
transfer heat from one flow to another flow. The plates and fins
are created from sheet metal material brazed together to define the
different flow paths. Thermal gradients present in the sheet
material create stresses that can be very high in certain
locations. The stresses are typically largest in one corner where
the hot side flow first meets the coldest portion of the cooling
flow. In an opposite corner where the coldest hot side flow meets
the hottest cold side flow the temperature difference is much less
resulting in unbalanced stresses across the heat exchanger
structure. Increasing temperatures and pressures can result in
stresses on the structure that can exceed material and assembly
capabilities.
[0002] Turbine engine manufactures utilize heat exchangers
throughout the engine to cool and condition airflow for cooling and
other operational needs. Improvements to turbine engines have
enabled increases in operational temperatures and pressures. The
increases in temperatures and pressures improve engine efficiency
but also increase demands on all engine components including heat
exchangers.
[0003] Turbine engine manufacturers continue to seek further
improvements to engine performance including improvements to
thermal, transfer and propulsive efficiencies.
SUMMARY
[0004] In a featured embodiment, a heat exchanger includes a plate
portion including a top surface, bottom surface, a leading edge, a
trailing edge and a plurality of internal passages extending
between an inlet and an outlet. A fin portion extends outward from
one of the top surface and the bottom surface. The fin portion and
the leading edge of the plate portion define a leading edge
contour.
[0005] In another embodiment according to the previous embodiment,
the fin portion and trailing edge of the plate portion define a
trailing edge contour.
[0006] In another embodiment according to any of the previous
embodiments, the leading edge contour and the trailing edge contour
are disposed within a plane transverse to the plurality of internal
passages.
[0007] In another embodiment according to any of the previous
embodiments, the plurality of internal passages include one of an
elliptical shape and a rectilinear shape in cross-section.
[0008] In another embodiment according to any of the previous
embodiments, the fin portion includes a fin thickness in
cross-section that varies between the leading edge and the trailing
edge.
[0009] In another embodiment according to any of the previous
embodiments, the fin thickness is largest at the leading edge.
[0010] In another embodiment according to any of the previous
embodiments, the fin portion includes a plurality of bottom fin
portions extending outward from the bottom surface and a plurality
of top fin portions extending outward from the top surface. Each of
the plurality of top fin portions are offset from the plurality of
top fin portions.
[0011] In another embodiment according to any of the previous
embodiments, an inlet manifold is in fluid communication with the
inlet and an outlet manifold is in fluid communication with the
outlet.
[0012] In another embodiment according to any of the previous
embodiments, the plate portion and the fin portion include a single
unitary cast item.
[0013] In another featured embodiment, a cast plate for a heat
exchanger includes a plate portion including a top surface, bottom
surface, a leading edge, a trailing edge and a plurality of
internal passages extending between an inlet and an outlet. A
plurality of bottom fin portions extend outward from the bottom
surface and a plurality of top fin portions extend outward from the
top surface. Each of the plurality of top fin portions are offset
from the plurality of top fin portions. At least one of the
plurality of top fin portions and the bottom fin portions define a
leading edge contour common with the leading edge of the plate
portion.
[0014] In another embodiment according to the previous embodiment,
at least one of the plurality of top fin portions and the bottom
fin portions define a trailing edge contour common with the
trailing edge of the plate portion.
[0015] In another embodiment according to any of the previous
embodiments, the leading edge contour and the trailing edge contour
are disposed within respective planes transverse to the plurality
of internal passages.
[0016] In another embodiment according to any of the previous
embodiments, the plurality of internal passages include one of an
elliptical shape and a rectilinear shape in cross-section.
[0017] In another embodiment according to any of the previous
embodiments, each of the plurality of top fin portions and bottom
fin portions includes a fin thickness that is largest at the
leading edge.
[0018] In another featured embodiment, a method of building a heat
exchanger includes forming a core defining a plurality of internal
passages through a plate portion. The core is inserted within a
mold cavity that defines outer surfaces of the plate portion to
include a top surface, bottom surface, a leading edge, a trailing
edge and plurality of fin portions extending outward from one of
the top surface and the bottom surface. The plurality of fin
portions and the leading edge of the plate portion are defined to
form a leading edge contour. Cast material is introduced into the
mold to form a single unitary heat exchanger plate without a joint
between the plate portion and the plurality of fin portions. The
heat exchanger plate is removed from the mold and removes the core
from the plate portion.
[0019] In another embodiment according to the previous embodiment,
the plurality of fin portions and the trailing edge of the plate
are defined to form a trailing edge contour.
[0020] In another embodiment according to any of the previous
embodiments, the mold cavity includes features for defining fin
portions on both the top surface and the bottom surface that are
offset relative to each other.
[0021] In another embodiment according to any of the previous
embodiments, the plurality of fins are cast to include a fin
thickness that is largest at the leading edge.
[0022] Although the different examples have the specific components
shown in the illustrations, embodiments of this disclosure are not
limited to those particular combinations. It is possible to use
some of the components or features from one of the examples in
combination with features or components from another one of the
examples.
[0023] These and other features disclosed herein can be best
understood from the following specification and drawings, the
following of which is a brief description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 is a perspective view of an example heat
exchanger.
[0025] FIG. 2 is a perspective view of an example plate according
to an example embodiment.
[0026] FIG. 3 is an enlarged view of the leading edge of the
example plate embodiment.
[0027] FIG. 4 is a cross-sectional view of a portion of the example
plate embodiment.
[0028] FIG. 5 is a sectional view of a trailing edge of the example
plate embodiment.
[0029] FIG. 6 is another example view of a leading edge of the
example plate embodiment.
[0030] FIG. 7 is a partial sectional view of a trailing edge of the
example plate embodiment.
[0031] FIG. 8 is an enlarged view of a portion of another example
plate embodiment.
[0032] FIG. 9 is a top view of a fin for the example plate
embodiments.
[0033] FIG. 10 is a schematic representation of a method of
fabricating an example plate.
DETAILED DESCRIPTION
[0034] Referring to FIG. 1, a heat exchanger 10 is shown and
includes a plurality of plates 15 stacked between an inlet manifold
14 and an outlet manifold 16. The plurality of plates 15 define
passages for a hot flow schematically shown at 18 that flows
through the plates 15 and is cooled by an external cooling flow 20
that flows along an outer surface of each of the plurality of
plates 15. Each of the plates 15 includes a leading edge 22 that
first encounters the initial incoming cooling airflow 20 and a
trailing edge 24 where the cooling airflow 24 is exhausted. It
should be understood that although a plurality of plates 15 are
shown, it is within the contemplation of this disclosure that any
number of plates 15 including a single plate 15 could be utilized
for the heat exchanger 10.
[0035] Referring to FIG. 2 with continued reference to FIG. 1, each
of the example plate 15 is an integrally formed structure that
includes a plate portion 12 and a plurality of upper fins 34
extending from a top surface 26 of the plate portion 12. The plate
portion 12 includes a bottom surface 28 from which a plurality of
bottom fins 36 extend. The plate portion 12 defines a plurality of
internal passages 38 that extends from an inlet 30 to an outlet 32.
The passages 38 are for a fluid flow that is cooled and are
provided transverse to the plurality of upper fins 34 and bottom
fins 36. The fins 34, 36 are integral portions of the plate 15 and
extend from the top surface 26 and bottom surface 28. Each of the
fins 34, 36 extend longitudinally from the leading edge 22 to the
trailing edge 24.
[0036] Referring to FIG. 3 with continued reference to FIG. 2, each
of the fins 34, 36 extends to the leading edge 22 and defines a
portion of a leading edge contour 40 that corresponds with the
leading edge 22 of the plate portion 12. In the embodiment
illustrated in FIG. 3, the top fin 34 extends along the top surface
26 between the leading edge 22 and the trailing edge 24. At the
leading edge 22 of the plate portion 12, the fin 34 forms the
leading edge contour 40 that includes the leading edge 22 of the
plate portion 12 along with the leading edge of the top fin 34. The
contoured leading edge 40 is an integrated shape that improves
aerodynamic performance and fluid flow to improve heat transfer
efficiency. Additionally, because the fins 34 extend all the way to
the leading edge 22 of the plate portion 12, the leading edge 22
has increased ability to survive debris impact.
[0037] Referring to FIG. 4 with continued reference to FIGS. 2 and
3, the plate 15 is shown in a cross-sectional side view showing
that the top fins 34 are disposed within a first plane 42 and the
bottom fins 36 are disposed in a separate second plane 44 that is
spaced a distance 46 from the first plane 42 of the top fins 34.
Accordingly, the top fins 34 are offset relative to the bottom fins
36 to enable stacking of the plates 15 to scale the heat exchanger
10 to application specific requirements.
[0038] Referring to FIG. 5 with continued reference to FIGS. 2 and
3, a trailing edge contour 48 is shown at a trailing edge 24 of the
plate portion 12. The trailing edge contour 48 includes the
trailing edge 24 of the plate portion 12 that is disposed along the
common contour surface 48 with the upper fin 34 at the trailing
edge 24.
[0039] Referring to FIGS. 6 and 7, the leading edge contour 40 and
trailing edge contour 48 are also applicable to the bottom fins 36
that are interspersed and spaced along the bottom surface of the
plate portion 12.
[0040] Referring to FIG. 8, another plate embodiment is
schematically shown at 50 and includes an upper fin 34 and lower
fin 36 that merge to provide a common contour 52 at the leading
edge 22. In this example embodiment, the upper fin 34 and the lower
fin 36 are disposed in a common plane such that they both form a
portion of the common leading edge contour 52 with a leading edge
portion of the plate portion 12. In this example embodiment, the
upper fin 34 extends to the leading edge 22 just as the lower fin
36 does and both form a portion of the continuous contour 52 that
extends from the top fin 34 to the top of the bottom fin 36.
[0041] In the previous figures, the passages 38 are disclosed by
way of example as elongated elliptical shapes. In the example
disclosed in FIG. 8, the passages 54 are shown as rectangular
shaped. The shape of the passages 38, 54 could be different than
those shown and described within the contemplation of this
disclosure. Non-circular shaped passages can generate high stress
locations, particularly in those areas that are exposed to the
highest thermal differences between the incoming hot flow and the
cooling air flow. The leading edge counter 40 and the trailing edge
contour 48 provide increased thicknesses within the highest stress
regions of the plate 15. The increased thickness reduce the
stresses encountered as well as preventing potential deflections.
Moreover, the integral structure of the plate portions 12 and fin
portions 34, 36 enable a shifting and spreading of stresses into
the fins 34, 36. The spreading of stresses over additional area and
features of each plate 15 improves durability and capabilities to
operation at higher temperatures and pressures.
[0042] Referring to FIG. 9, one of the fins 34 and 36 is shown
schematically from a top down perspective to illustrate a fin
thickness 56 in a direction parallel to the internal passages 38.
The thickness 56 varies along the length of each of the fins 34, 36
and is at its greatest portion at a fillet 60 near a leading edge
22 of the plate portion 12. The increased thickness 58 at the
leading edge 22 of the plate portion 12 provides increased
survivability of the heat exchanger to survive potential debris
impact. The increased thickness 58 at the fillet 60 also provides
increased protection against cracks and other stresses generated
due to thermal gradients encountered during operation.
[0043] Referring to FIG. 10, an example method of fabricating a
plate 15 is schematically illustrated and shown at 62 and includes
the initial step of forming a core 64. The core 64 is formed to
include structures 70 to define the internal passages of a
completed cast plate 15. The core 64 is formed from a material that
is compatible with the cast material 68 and that can be removed.
The core 64 is inserted into a mold 66 that includes cavity
surfaces 72 that define the outer surfaces of a completed plate 15.
The mold 66 may include several cavities to hold several cores 64
as is understood by those skilled in molding arts. The molten cast
material 68 utilized to fabricate the plate 15 is schematically
shown and introduced into the mold 66 to form the completed plate
15. Once the material 68 has fully cured, the plate 15 is removed
from the mold 66 and the core 64 removed by known removal process.
It should be understood that although a method of fabricating the
example cast plate 15 is described by way of example, other molding
and casting methods and processes could be utilized and are within
the contemplation of this disclosure.
[0044] The resulting plate 15 is an integral single unitary part
that includes the plate portion 12 that defines the internal
passages 38 and a plurality of integrally formed cooling fins 34,
36 extending from the top and bottom surfaces 26, 28. Moreover,
each of the fins 34, 36 includes features that provide increased
survivability at the leading and trailing edges 22, 24 of the plate
15 to improve impact survivability and also to accommodate thermal
stresses caused by thermal gradients encountered during
operation.
[0045] Although an example embodiment has been disclosed, a worker
of ordinary skill in this art would recognize that certain
modifications would come within the scope of this disclosure. For
that reason, the following claims should be studied to determine
the scope and content of this disclosure.
* * * * *