U.S. patent application number 16/054253 was filed with the patent office on 2020-02-06 for counter flow heat exchanger.
The applicant listed for this patent is Hamilton Sundstrand Corporation. Invention is credited to Ahmet Becene, Feng Feng, Luke Martin, Patrick McCord, Nigel Palmer, Gabriel Ruiz, James Streeter, Joseph Turney.
Application Number | 20200041212 16/054253 |
Document ID | / |
Family ID | 67438881 |
Filed Date | 2020-02-06 |
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United States Patent
Application |
20200041212 |
Kind Code |
A1 |
Palmer; Nigel ; et
al. |
February 6, 2020 |
COUNTER FLOW HEAT EXCHANGER
Abstract
A counter-flow heat exchanger including: a primary flow
passageway comprising a primary flow inlet, a primary flow outlet,
and a plurality of primary flow subset passageways therebetween; a
secondary flow passageway comprising a secondary flow inlet, a
secondary flow outlet, and a plurality of secondary flow subset
passageways therebetween; and a heat exchanger core comprising
portions of the plurality of primary flow subset passageways and
the plurality of secondary flow subset passageways, the secondary
flow passageway being in thermal communication with the primary
flow passageway in the heat exchanger core, wherein the primary
flow subset passageways in the heat exchanger core and the
secondary flow subset passageways in the heat exchanger core are
oriented such that primary fluid flow through the primary flow
subset passageways flows opposite secondary fluid flow through the
secondary flow subset passageways.
Inventors: |
Palmer; Nigel; (West Granby,
CT) ; Becene; Ahmet; (West Simsbury, CT) ;
McCord; Patrick; (Norwich, CT) ; Streeter; James;
(Torrington, CT) ; Feng; Feng; (South Windsor,
CT) ; Martin; Luke; (Enfield, CT) ; Ruiz;
Gabriel; (Granby, CT) ; Turney; Joseph;
(Amston, CT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Hamilton Sundstrand Corporation |
Charlotte |
NC |
US |
|
|
Family ID: |
67438881 |
Appl. No.: |
16/054253 |
Filed: |
August 3, 2018 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F28D 7/1607 20130101;
F28F 2255/18 20130101; F28F 1/025 20130101; F28F 2210/02 20130101;
F28D 7/0008 20130101; F28F 9/0256 20130101; F28D 7/0033 20130101;
F28D 2021/0021 20130101; F28D 2021/0026 20130101; F28D 9/0081
20130101; F28D 7/1646 20130101; F28F 9/0275 20130101; F28F 7/02
20130101 |
International
Class: |
F28D 7/16 20060101
F28D007/16; F28D 7/00 20060101 F28D007/00; F28D 9/00 20060101
F28D009/00; F28F 9/02 20060101 F28F009/02; F28F 1/02 20060101
F28F001/02 |
Claims
1. A counter-flow heat exchanger, comprising: a primary flow
passageway comprising a primary flow inlet, a primary flow outlet,
and a plurality of primary flow subset passageways therebetween; a
secondary flow passageway comprising a secondary flow inlet, a
secondary flow outlet, and a plurality of secondary flow subset
passageways therebetween; and a heat exchanger core comprising
portions of the plurality of primary flow subset passageways and
the plurality of secondary flow subset passageways, the secondary
flow passageway being in thermal communication with the primary
flow passageway in the heat exchanger core, wherein the primary
flow subset passageways in the heat exchanger core and the
secondary flow subset passageways in the heat exchanger core are
oriented such that primary fluid flow through the primary flow
subset passageways flows opposite secondary fluid flow through the
secondary flow subset passageways.
2. The counter-flow heat exchanger of claim 1, wherein the primary
flow passageway further comprises a primary flow inlet fractal
header fluidly connecting the primary flow inlet to each of the
plurality of primary flow subset passageways, the primary flow
inlet fractal header being configured to fractally branch the fluid
flow from a single passageway at the primary flow inlet to the
plurality of primary flow subset passageways.
3. The counter-flow heat exchanger of claim 1, wherein the
secondary flow passageway further comprises a secondary flow inlet
fractal header fluidly connecting the secondary flow inlet to each
of the plurality of secondary flow subset passageways, the
secondary flow inlet fractal header being configured to fractally
branch the fluid flow from a single passageway at the secondary
flow inlet to the plurality of secondary flow subset
passageways.
4. The counter-flow heat exchanger of claim 2, wherein the
secondary flow passageway further comprises a secondary flow inlet
fractal header fluidly connecting the secondary flow inlet to each
of the plurality of secondary flow subset passageways, the
secondary flow inlet fractal header being configured to fractally
branch the fluid flow from a single passageway at the secondary
flow inlet to the plurality of secondary flow subset
passageways.
5. The counter-flow heat exchanger of claim 1, wherein the primary
flow passageway further comprises a primary flow outlet fractal
header fluidly connecting the primary flow outlet to each of the
plurality of primary flow subset passageways, the primary flow
outlet fractal header being configured to fractally unify the
primary flow subset passageways to a single passageway at the
primary flow outlet.
6. The counter-flow heat exchanger of claim 1, wherein the
secondary flow passageway further comprises a secondary flow outlet
fractal header fluidly connecting the secondary flow outlet to each
of the plurality of secondary flow subset passageways, the
secondary flow outlet fractal header being configured to fractally
unify the secondary flow subset passageways to a single passageway
at the secondary flow outlet.
7. The counter-flow heat exchanger of claim 2, wherein the primary
flow passageway further comprises a primary flow outlet fractal
header fluidly connecting the primary flow outlet to each of the
plurality of primary flow subset passageways, the primary flow
outlet fractal header being configured to fractally unify the
primary flow subset passageways to a single passageway at the
primary flow outlet.
8. The counter-flow heat exchanger of claim 3, wherein the
secondary flow passageway further comprises a secondary flow outlet
fractal header fluidly connecting the secondary flow outlet to each
of the plurality of secondary flow subset passageways, the
secondary flow outlet fractal header being configured to fractally
unify the secondary flow subset passageways to a single passageway
at the secondary flow outlet.
9. The counter-flow heat exchanger of claim 4, wherein the primary
flow passageway further comprises a primary flow outlet fractal
header fluidly connecting the primary flow outlet to each of the
plurality of primary flow subset passageways, the primary flow
outlet fractal header being configured to fractally unify the
primary flow subset passageways to a single passageway at the
primary flow outlet.
10. The counter-flow heat exchanger of claim 4, wherein the
secondary flow passageway further comprises a secondary flow outlet
fractal header fluidly connecting the secondary flow outlet to each
of the plurality of secondary flow subset passageways, the
secondary flow outlet fractal header being configured to fractally
unify the secondary flow subset passageways to a single passageway
at the secondary flow outlet.
11. The counter-flow heat exchanger of claim 10, wherein the
primary flow passageway further comprises a primary flow outlet
fractal header fluidly connecting the primary flow outlet to each
of the plurality of primary flow subset passageways, the primary
flow outlet fractal header being configured to fractally unify the
primary flow subset passageways to a single passageway at the
primary flow outlet.
12. The counter-flow heat exchanger of claim 1, wherein the
counter-flow heat exchanger is built in a single piece using
additive manufacturing.
13. The counter-flow heat exchanger of claim 1, wherein multiple
linearly extending cylinders form each individual primary flow
subset passageway and each individual secondary flow subset
passageway within the heat exchanger core.
14. The counter-flow heat exchanger of claim 1, wherein multiple
curvilinear extending cylinders form each individual primary flow
subset passageway and each individual secondary flow subset
passageway within the heat exchanger core.
15. The counter-flow heat exchanger of claim 1, wherein the heat
exchanger core is composed of parallel alternating layers of the
primary flow subset passageways and the secondary flow subset
passageways.
16. The counter-flow heat exchanger of claim 1, wherein at least
one of the primary flow subset passageways and the secondary flow
subset passageways are circular in shape.
17. The counter-flow heat exchanger of claim 1, wherein the primary
flow subset passageways are physically connected to the secondary
flow subset passageways within the heat exchanger core.
18. A method of manufacturing a counter-flow heat exchanger, the
method comprising: forming a counter-flow heat exchanger using
additive manufacturing, the counter flow heat exchanger comprising:
a primary flow passageway comprising a primary flow inlet, a
primary flow outlet, and a plurality of primary flow subset
passageways therebetween; a secondary flow passageway comprising a
secondary flow inlet, a secondary flow outlet, and a plurality of
secondary flow subset passageways therebetween; and a heat
exchanger core comprising portions of the plurality of primary flow
subset passageways and the plurality of secondary flow subset
passageways, the secondary flow passageway being in thermal
communication with the primary flow passageway in the heat
exchanger core, wherein the primary flow subset passageways in the
heat exchanger core and the secondary flow subset passageways in
the heat exchanger core are oriented such that primary fluid flow
through the primary flow subset passageways flows opposite
secondary fluid flow through the secondary flow subset
passageways.
19. The method of claim 18, wherein the additive manufacturing is
via direct metal laser sintering.
Description
BACKGROUND
[0001] The subject matter disclosed herein generally relates to the
field of heat exchangers, and more particularly to method and
apparatus for heat exchangers of aircraft.
[0002] Heat exchangers are conventionally utilized in aircraft to
removed heat from fluid flows. Heat exchangers utilized aircraft
must be designed to fit in limited volumes, which may reduce
overall heat exchange efficiency of the heat exchangers and/or
impede the flow of fluid through the heat exchanger.
BRIEF SUMMARY
[0003] According to one embodiment, a counter-flow heat exchanger
is provided. The counter-flow heat exchanger including: a primary
flow passageway comprising a primary flow inlet, a primary flow
outlet, and a plurality of primary flow subset passageways
therebetween; a secondary flow passageway comprising a secondary
flow inlet, a secondary flow outlet, and a plurality of secondary
flow subset passageways therebetween; and a heat exchanger core
comprising portions of the plurality of primary flow subset
passageways and the plurality of secondary flow subset passageways,
the secondary flow passageway being in thermal communication with
the primary flow passageway in the heat exchanger core, wherein the
primary flow subset passageways in the heat exchanger core and the
secondary flow subset passageways in the heat exchanger core are
oriented such that primary fluid flow through the primary flow
subset passageways flows opposite secondary fluid flow through the
secondary flow subset passageways.
[0004] In addition to one or more of the features described above,
or as an alternative, further embodiments may include that the
primary flow passageway further comprises a primary flow inlet
fractal header fluidly connecting the primary flow inlet to each of
the plurality of primary flow subset passageways, the primary flow
inlet fractal header being configured to fractally branch the fluid
flow from a single passageway at the primary flow inlet to the
plurality of primary flow subset passageways.
[0005] In addition to one or more of the features described above,
or as an alternative, further embodiments may include that the
secondary flow passageway further comprises a secondary flow inlet
fractal header fluidly connecting the secondary flow inlet to each
of the plurality of secondary flow subset passageways, the
secondary flow inlet fractal header being configured to fractally
branch the fluid flow from a single passageway at the secondary
flow inlet to the plurality of secondary flow subset
passageways.
[0006] In addition to one or more of the features described above,
or as an alternative, further embodiments may include that the
secondary flow passageway further comprises a secondary flow inlet
fractal header fluidly connecting the secondary flow inlet to each
of the plurality of secondary flow subset passageways, the
secondary flow inlet fractal header being configured to fractally
branch the fluid flow from a single passageway at the secondary
flow inlet to the plurality of secondary flow subset
passageways.
[0007] In addition to one or more of the features described above,
or as an alternative, further embodiments may include that the
primary flow passageway further comprises a primary flow outlet
fractal header fluidly connecting the primary flow outlet to each
of the plurality of primary flow subset passageways, the primary
flow outlet fractal header being configured to fractally unify the
primary flow subset passageways to a single passageway at the
primary flow outlet.
[0008] In addition to one or more of the features described above,
or as an alternative, further embodiments may include that the
secondary flow passageway further comprises a secondary flow outlet
fractal header fluidly connecting the secondary flow outlet to each
of the plurality of secondary flow subset passageways, the
secondary flow outlet fractal header being configured to fractally
unify the secondary flow subset passageways to a single passageway
at the secondary flow outlet.
[0009] In addition to one or more of the features described above,
or as an alternative, further embodiments may include that the
primary flow passageway further comprises a primary flow outlet
fractal header fluidly connecting the primary flow outlet to each
of the plurality of primary flow subset passageways, the primary
flow outlet fractal header being configured to fractally unify the
primary flow subset passageways to a single passageway at the
primary flow outlet.
[0010] In addition to one or more of the features described above,
or as an alternative, further embodiments may include that the
secondary flow passageway further comprises a secondary flow outlet
fractal header fluidly connecting the secondary flow outlet to each
of the plurality of secondary flow subset passageways, the
secondary flow outlet fractal header being configured to fractally
unify the secondary flow subset passageways to a single passageway
at the secondary flow outlet.
[0011] In addition to one or more of the features described above,
or as an alternative, further embodiments may include that the
primary flow passageway further comprises a primary flow outlet
fractal header fluidly connecting the primary flow outlet to each
of the plurality of primary flow subset passageways, the primary
flow outlet fractal header being configured to fractally unify the
primary flow subset passageways to a single passageway at the
primary flow outlet.
[0012] In addition to one or more of the features described above,
or as an alternative, further embodiments may include that the
secondary flow passageway further comprises a secondary flow outlet
fractal header fluidly connecting the secondary flow outlet to each
of the plurality of secondary flow subset passageways, the
secondary flow outlet fractal header being configured to fractally
unify the secondary flow subset passageways to a single passageway
at the secondary flow outlet.
[0013] In addition to one or more of the features described above,
or as an alternative, further embodiments may include that the
primary flow passageway further comprises a primary flow outlet
fractal header fluidly connecting the primary flow outlet to each
of the plurality of primary flow subset passageways, the primary
flow outlet fractal header being configured to fractally unify the
primary flow subset passageways to a single passageway at the
primary flow outlet.
[0014] In addition to one or more of the features described above,
or as an alternative, further embodiments may include that the
counter-flow heat exchanger is built in a single piece using
additive manufacturing.
[0015] In addition to one or more of the features described above,
or as an alternative, further embodiments may include that multiple
linearly extending cylinders form each individual primary flow
subset passageway and each individual secondary flow subset
passageway within the heat exchanger core.
[0016] In addition to one or more of the features described above,
or as an alternative, further embodiments may include that multiple
curvilinear extending cylinders form each individual primary flow
subset passageway and each individual secondary flow subset
passageway within the heat exchanger core.
[0017] In addition to one or more of the features described above,
or as an alternative, further embodiments may include that the heat
exchanger core is composed of parallel alternating layers of the
primary flow subset passageways and the secondary flow subset
passageways.
[0018] In addition to one or more of the features described above,
or as an alternative, further embodiments may include that at least
one of the primary flow subset passageways and the secondary flow
subset passageways are circular in shape.
[0019] In addition to one or more of the features described above,
or as an alternative, further embodiments may include that the
primary flow subset passageways are physically connected to the
secondary flow subset passageways within the heat exchanger
core.
[0020] According to another embodiment, a method of manufacturing a
counter-flow heat exchanger is provided. The method including:
forming a counter-flow heat exchanger using additive manufacturing,
the counter flow heat exchanger comprising: a primary flow
passageway comprising a primary flow inlet, a primary flow outlet,
and a plurality of primary flow subset passageways therebetween; a
secondary flow passageway comprising a secondary flow inlet, a
secondary flow outlet, and a plurality of secondary flow subset
passageways therebetween; and a heat exchanger core comprising
portions of the plurality of primary flow subset passageways and
the plurality of secondary flow subset passageways, the secondary
flow passageway being in thermal communication with the primary
flow passageway in the heat exchanger core, wherein the primary
flow subset passageways in the heat exchanger core and the
secondary flow subset passageways in the heat exchanger core are
oriented such that primary fluid flow through the primary flow
subset passageways flows opposite secondary fluid flow through the
secondary flow subset passageways.
[0021] In addition to one or more of the features described above,
or as an alternative, further embodiments may include that the
additive manufacturing is via direct metal laser sintering.
[0022] Technical effects of embodiments of the present disclosure
include manufacturing a counter-flow heat exchanger having fractal
headers using additive manufacturing.
[0023] The foregoing features and elements may be combined in
various combinations without exclusivity, unless expressly
indicated otherwise. These features and elements as well as the
operation thereof will become more apparent in light of the
following description and the accompanying drawings. It should be
understood, however, that the following description and drawings
are intended to be illustrative and explanatory in nature and
non-limiting.
BRIEF DESCRIPTION
[0024] The following descriptions should not be considered limiting
in any way. With reference to the accompanying drawings, like
elements are numbered alike:
[0025] FIG. 1 is a top view of a counter-flow heat exchanger,
according to an embodiment of the present disclosure; and
[0026] FIG. 2 is a cross-sectional view of a heat exchanger core of
the counter-flow heat exchanger, according to an embodiment of the
present disclosure.
DETAILED DESCRIPTION
[0027] A detailed description of one or more embodiments of the
disclosed apparatus and method are presented herein by way of
exemplification and not limitation with reference to the
Figures.
[0028] FIG. 1 is a top view of a counter-flow heat exchanger 100,
according to an embodiment of the present disclosure. The
counter-flow heat exchanger 100 may be utilized in a variety of
applications requiring thermal dynamic transfer of heat including
but not limited to an aircraft, a combustion engine, a car, a space
craft, a powerplant, a satellite, satellite, etc. In an embodiment,
the counter-flow heat exchanger 100 may be utilized in an aircraft.
In another embodiment, the counter-flow heat exchanger 100 may be
utilized in an aircraft air conditioning system.
[0029] The counter-flow heat exchanger 100 includes a heat
exchanger core 120 that may be oriented along a longitudinal axis
X. The counter-flow heat exchanger 100 includes a primary flow
passageway 102 and a secondary flow passageway 112 in thermal
communication with the primary flow passageway 102. In an
embodiment, the primary flow passageways 102 is configured to
convey a primary fluid 60 and the secondary flow passageway 112 is
configured to convey a secondary fluid 70. The primary fluid 60 may
be at a temperature greater than the secondary fluid 70. The
primary fluid 60 may be a liquid or a gas and the secondary fluid
70 may be a liquid or a gas. In another embodiment, the hot fluid
and the cooling fluid may be airflow.
[0030] The counter-flow heat exchanger 100 includes a primary flow
inlet 104, a primary flow outlet 106, and a plurality of primary
flow subset passageways 108 therebetween. The flow direction of the
primary fluid 60 is indicated schematically by the arrow 101. In an
embodiment, the primary flow subset passageways 108 in the heat
exchanger core 120 and the secondary flow subset passageways 118 in
the heat exchanger core 120 are oriented such that primary fluid
flow 60 through the primary flow subset passageways 108 flows
opposite secondary fluid flow 70 through the secondary flow subset
passageways 118.
[0031] The primary flow inlet 104 is fluidly connected to the
primary flow subset passageways 108 by a primary flow inlet fractal
header 103. The primary flow passageway 102 may be a single fluid
passageway at the primary flow inlet 104 and then branches out into
multiple primary flow subset passageways 108. The primary flow
passageway 102 may branch out into two or more primary flow subset
passageways 108. The primary flow passageway 102 may branch out
into the multiple primary flow subset passageways 108 in
progressive steps. For example, as shown in FIG. 2, the primary
flow passageway 102 may branch out from a single fluid passageway
at the primary flow inlet 104 into two primary flow subset
passageways 108 that each branch into four primary flow subset
passageways 108 (i.e., eight primary flow subset passageways 108 in
total) that each branch into four primary flow subset passageways
108, thus bringing the total to thirty-two primary flow subset
passageways 108. The primary flow inlet fractal header 103 is
configured to fractally branch the fluid flow from the single
passageway at the primary flow inlet 104 to the plurality of
primary flow subset passageways 108, such that pressure drops in
the primary fluid 60 flowing through the primary flow inlet fractal
header 103 is optimized and/or reduced. In an embodiment, the
primary flow subset passageways 108 includes thirty-two separate
fluid passageways, thus the primary flow inlet fractal header 103
divides the primary fluid 60 flow from a single passageway at the
primary flow inlet 104 to thirty-two separate primary flow subset
passageways 108. Advantageously, the primary flow inlet fractal
header 103 gently divides the primary fluid 60 flow into separate
primary flow subset passageways 108 in accordance with the physical
flow characteristics of the primary fluid 60 to avoid large
pressure drops in the fluid. The shape and flow area of the
transition regions where the primary flow subset passageways 108
branch out are designed to minimize recirculation zones and to
provide a uniform amount of flow to each branch.
[0032] The primary flow outlet 106 is fluidly connected to the
primary flow subset passageways 108 by a primary flow outlet
fractal header 105. The primary flow passageway 102 fractally
unifies (i.e., branch down) the plurality of primary flow subset
passageways 108 to a single fluid passageway at the primary flow
outlet 106. The primary flow passageway 102 may unify from the two
or more primary flow subset passageways 108. The primary flow
passageway 102 unifies from the multiple primary flow subset
passageways 108 in progressive steps. For example, as shown in FIG.
2, the primary flow passageway 102 may unify from the thirty-two
primary flow subset passageways 108 down to eight primary flow
subset passageways 108, then from the eight primary flow subset
passageways 108 down to two primary flow subset passageways 108
that unify into to a single fluid passageway at the primary flow
outlet 106. The primary flow outlet fractal header 105 is
configured to fractally unify the primary flow subset passageways
108 to a single passageway at the primary flow outlet 106, such
that pressure drops in the primary fluid 60 flowing through the
primary flow outlet fractal header 105 is optimized and/or reduced.
In an embodiment, the primary flow subset passageways 108 includes
thirty-two separate fluid passageways, thus the primary flow outlet
fractal header 105 unifies the primary fluid 60 flow from
thirty-two separate primary flow subset passageways 108 to a single
passageway at the primary flow outlet 106. Advantageously, the
primary flow outlet fractal header 105 gently unifies the primary
fluid 60 flow from separate primary flow subset passageways 108
into a single fluid passageway in accordance with the physical flow
characteristics of the primary fluid 60 to avoid large pressure
drops in the fluid. The shape and flow area of the transition
regions where the primary flow subset passageways 108 unify are
designed to minimize recirculation zones and turbulence due to
mixing of the flows from each branch.
[0033] The counter-flow heat exchanger 100 includes a secondary
flow inlet 114, a secondary flow outlet 116, and a plurality of
secondary flow subset passageways 118 therebetween. The flow
direction of the secondary fluid 70 is indicated schematically by
the arrow 111.
[0034] The secondary flow inlet 114 is fluidly connected to the
secondary flow subset passageways 118 by a secondary flow inlet
fractal header 113. The secondary flow passageway 112 may be a
single fluid passageway at the secondary flow inlet 114 and then
branches out into multiple secondary flow subset passageways 118.
The secondary flow passageway 112 may branch out into two or more
secondary flow subset passageways 118. The secondary flow
passageway 112 may branch out into the multiple secondary flow
subset passageways 118 in progressive steps. For example, as shown
in FIG. 2, the secondary flow passageway 112 may branch out from a
single fluid passageway at the secondary flow inlet 114 into two
secondary flow subset passageways 118 that each branch into four
secondary flow subset passageways 118 (i.e., eight secondary flow
subset passageways 118 in total) that each branch into four
secondary flow subset passageways 118, thus bringing the total to
thirty-two secondary flow subset passageways 118. The secondary
flow inlet fractal header 113 is configured to fractally branch the
fluid flow from the single passageway at the secondary flow inlet
114 to the multiple fluid passageways in the secondary flow subset
passageways 118, such that pressure drops in the secondary fluid 70
flowing through the secondary flow inlet fractal header 113 is
optimized and/or reduced. In an embodiment, the secondary flow
subset passageways 118 includes thirty-two separate fluid
passageways, thus the secondary flow inlet fractal header 113
divides the secondary fluid 70 flow from a single passageway at the
secondary flow inlet 114 to thirty-two separate secondary flow
subset passageways 118. Advantageously, the secondary flow inlet
fractal header 113 gently divides the secondary fluid 70 flow into
separate secondary flow subset passageways 118 in accordance with
the physical flow characteristics of the secondary fluid 70 to
avoid large pressure drops in the fluid. The shape and flow area of
the transition regions where the secondary flow subset passageways
118 branch out are designed to minimize recirculation zones and to
provide a uniform amount of flow to each branch.
[0035] The secondary flow outlet 116 is fluidly connected to the
secondary flow subset passageways 118 by a secondary flow outlet
fractal header 115. The secondary flow passageway 112 unify (i.e.,
branch down) the plurality of secondary flow subset passageways 118
to a single fluid passageway at the secondary flow outlet 116. The
secondary flow passageway 112 may unify from the two or more
secondary flow subset passageways 118. The secondary flow
passageway 112 unifies from the multiple secondary flow subset
passageways 118 in progressive steps. For example, as shown in FIG.
2, the secondary flow passageway 112 may unify from the thirty-two
secondary flow subset passageways 118 down to eight secondary flow
subset passageways 118, then from the eight secondary flow subset
passageways 118 down to two secondary flow subset passageways 118
that unify into to a single fluid passageway at the secondary flow
outlet 116. The secondary flow outlet fractal header 115 is
configured to fractally unify the secondary flow subset passageways
118 to a single passageway at the secondary flow outlet 116, such
that pressure drops in the secondary fluid 70 flowing through the
secondary flow outlet fractal header 115 is optimized and/or
reduced. In an embodiment, the secondary flow subset passageways
118 includes thirty-two separate fluid passageways, thus the
secondary flow outlet fractal header 115 unifies the secondary
fluid 70 flow from thirty-two separate secondary flow subset
passageways 118 to a single passageway at the secondary flow outlet
116. Advantageously, the secondary flow outlet fractal header 115
gently unifies the secondary fluid 70 flow from separate secondary
flow subset passageways 118 into a single fluid passageway in
accordance with the physical flow characteristics of the secondary
fluid 70 to avoid large pressure drops in the fluid. The shape and
flow area of the transition regions where the secondary flow subset
passageways 118 unify are designed to minimize recirculation zones
and turbulence due to mixing of the flows from each branch.
[0036] Referring now to FIGS. 1 and 2. As shown in FIG. 1, in the
heat exchanger core 120, the flow direction of the secondary fluid
70 as indicated schematically by the arrow 111 is directly opposite
of the flow direction of the primary fluid 60 as indicated
schematically by the arrow 101. While the heat exchanger core 120
is shown as a straight section in FIG. 1, the actual heat exchanger
core 120 may be bent in one or more planes to accommodate for local
interferences. FIG. 2 is a cross-sectional view of the heat
exchanger core 120, according to an embodiment of the present
disclosure. FIG. 2 shows that the heat exchanger core 120 may be
composed of parallel alternating layers of primary flow subset
passageways 108 and secondary flow subset passageways 118. As shown
in FIG. 2, the primary flow subset passageways 108 and secondary
flow subset passageways 118 may be circular in shape. The primary
flow subset passageways 108 and secondary flow subset passageways
118 may also be shaped in various other shapes including but not
limited to hexagons, rectangular, non-regular, or any other
geometric shapes/sections needed to maximize heat transfer and
structural needs. Further, the shape of the primary flow subset
passageways 108 may differ from the shapes of the secondary flow
subset passageway 118. Additionally, each individual primary flow
subset passageway 108 may have different shapes and each individual
secondary flow subset passageway 118 may have different shapes. The
shapes of each individual primary flow subset passageway 108 need
not be symmetric within a flow layer or between flow layers of the
heat exchanger core 120. Also, the shapes of each individual
secondary flow subset passageway 118 need not be symmetric within a
flow layer or between flow layers of the heat exchanger core 120.
Although shown at a right angle in FIG. 1, the heat exchanger core
120 may be oriented at any angle in any plane relative to the
primary flow inlet 104, the primary flow outlet 106, the secondary
flow inlet 114, and/or the secondary flow outlet 116.
[0037] The counter-flow heat exchanger 100 may be formed using
additive manufacturing such as, for, example, direct metal laser
sintering. It is contemplated that the heat exchanger core 120 can
be manufactured in a vertical direction, e.g. along vertical axis Z
to build the heat exchanger core 120 along with the rest of the
counter-flow heat exchanger 100 in a single piece. In an
embodiment, the primary flow subset passageways 108 are physically
connected to the secondary flow subset passageways 118 within the
heat exchanger core 120, as shown in FIG. 2. It is also
contemplated the heat exchanger core 120 can be composed of
multiple linearly extending cylinders forming each individual
primary flow subset passageway 108 and each individual secondary
flow subset passageway 118 within the heat exchanger core 120. It
is also contemplated that instead of being composed of multiple
linearly extending cylinders, the heat exchanger core 120 could be
built along a curvilinear path (i.e., non-linear, sinusoidal path)
creating wavy or ruffled sets of passageways as opposed to straight
ones for increased heat transfer or bend around obstructions.
[0038] The term fractal may be defined as a complex geometric
pattern exhibiting self-similarity in that small details of its
structure viewed at any scale repeat elements of the overall
pattern. Advantageously, the fractals headers 103, 105, 113, 115,
serve to gradually ease the transition between a single fluid
passageway and multiple fluid passageways with minimal interference
to the fluid flow. The term "about" is intended to include the
degree of error associated with measurement of the particular
quantity based upon the equipment available at the time of filing
the application. For example, "about" can include a range of .+-.8%
or 5%, or 2% of a given value.
[0039] The terminology used herein is for the purpose of describing
particular embodiments only and is not intended to be limiting of
the present disclosure. As used herein, the singular forms "a",
"an" and "the" are intended to include the plural forms as well,
unless the context clearly indicates otherwise. It will be further
understood that the terms "comprises" and/or "comprising," when
used in this specification, specify the presence of stated
features, integers, steps, operations, elements, and/or components,
but do not preclude the presence or addition of one or more other
features, integers, steps, operations, element components, and/or
groups thereof.
[0040] While the present disclosure has been described with
reference to an exemplary embodiment or embodiments, it will be
understood by those skilled in the art that various changes may be
made and equivalents may be substituted for elements thereof
without departing from the scope of the present disclosure. In
addition, many modifications may be made to adapt a particular
situation or material to the teachings of the present disclosure
without departing from the essential scope thereof. Therefore, it
is intended that the present disclosure not be limited to the
particular embodiment disclosed as the best mode contemplated for
carrying out this present disclosure, but that the present
disclosure will include all embodiments falling within the scope of
the claims.
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