Heat exchanger with barrier passages

Patent metadata

Field	Value
Publication number	US-11255614-B2
Application number	US-201916525560-A
Country	US
Kind code	B2
Filing date	Jul 29, 2019
Priority date	Jul 29, 2019
Publication date	Feb 22, 2022
Grant date	Feb 22, 2022

Abstract

A heat exchanger core consists of first and second fluid channels, each configured to direct flow of respective fluids through the heat exchanger core. Each first fluid channel includes first fluid flow assemblies having inner channels formed by inner channel walls that contain the first fluid, each inner channel surrounded by a barrier channel having a barrier channel wall that isolates the barrier channel from the second fluid. One or more barrier channel vanes support the inner channel within the barrier channel. Each barrier channel provides a void space between the inner channel wall and the barrier channel wall, thereby fluidly separating the first fluid from the second fluid. Each barrier channel can receive the first or second fluid in the event of a breach of the inner channel wall or the barrier channel wall, thereby preventing intra-fluid contamination.

First claim

The invention claimed is:

1. A heat exchanger configured to transfer heat between a first fluid and a second fluid, the first fluid being fluidly isolated from the second fluid, the heat exchanger comprising:
a heat exchanger core comprising:
a plurality of first fluid flow assemblies, each configured to direct flow of the first fluid through the heat exchanger core, each of the first fluid flow assemblies comprising:
a plurality of inner channels, each formed by an associated inner channel wall and configured to contain the first fluid; and
a plurality of barrier channels, each surrounding an associated inner channel; and

one or more second fluid channels, each configured to channel flow of the second fluid through the heat exchanger core;
wherein:
each of the plurality of barrier channels comprises:
a barrier channel wall, configured to isolate the barrier channel from the second fluid; and
one or more barrier channel vanes, configured to support the inner channel within the barrier channel;

each of the barrier channels is configured to provide a void space between the inner channel wall and the barrier channel wall, thereby fluidly separating the first fluid from the second fluid; and
each of the barrier channels is configured to receive the first fluid in the event of a breach of the inner channel wall and receive the second fluid in the event of a breach of the barrier channel wall;

an inlet plenum configured to receive the first fluid from a first fluid inlet, the inlet plenum comprising a plurality of plenum vanes defining the plurality of inner channels therebetween, each of the plurality of inner channels sandwiched between two barrier channels;
an outlet plenum configured to discharge the first fluid to a first fluid outlet, the outlet plenum comprising a plurality of plenum vanes defining the plurality of inner channels therebetween, each of the plurality of inner channels sandwiched between two barrier channels;
an inlet transition region, disposed between the inlet plenum and the heat exchanger core, the inlet transition region configured to change an orientation of each of the plurality of inner channels and respective barrier channels of the plurality of barrier channels from a sandwiching configuration to a coaxial configuration; and
an outlet transition region, disposed between the heat exchanger core and the outlet plenum, the outlet transition region configured to change an orientation of each of the plurality of inner channels and respective barrier channels of the plurality of barrier channels from a coaxial configuration to a sandwiching configuration.

2. The heat exchanger of claim 1 , wherein:
the first fluid inlet defines a first fluid inlet flow axis;
each of the plurality of inlet channels defines a core flow axis;
the inlet plenum changes a direction of the first fluid flow from the first fluid inlet flow axis to the core flow axis by an angle that ranges from 0-120 degrees;
the first fluid outlet defines a first fluid outlet flow axis; and
the outlet plenum changes the direction of the first fluid flow from the core flow axis to the first fluid outlet flow axis by an angle that ranges from 0-120 degrees.

3. The heat exchanger of claim 2 , wherein:
the inlet plenum changes the direction of the first fluid flow from the first fluid inlet flow axis to the core flow axis by an angle that is 90 degrees; and
the outlet plenum changes the direction of the first fluid flow from the core flow axis to the first fluid outlet flow axis by an angle that is 90 degrees.

4. The heat exchanger of claim 1 , wherein:
each of the one or more second fluid channels defines a second fluid channel height; and
the second fluid channel height ranges from 0.05-0.5 inch (1.3-13 mm).

5. The heat exchanger of claim 1 , wherein:
two horizontally-adjacent first fluid flow assemblies define a horizontal spacing;
the horizontal spacing ranges from 0.1-1 inch (2.5-25 mm);
two vertically-adjacent first fluid flow assemblies define a vertical spacing; and
the vertical spacing ranges from 0.1-1 inch (2.5-25 mm).

6. The heat exchanger of claim 1 , wherein:
each of the plurality of inner channels comprises a circular cross-sectional shape;
each of the plurality of barrier channels comprises a circular cross-sectional shape;
each of the plurality of inner channels defines an inner channel diameter;
the inner channel diameter ranges from 0.05-0.5 inch (1.3-13 mm);
each of the plurality of barrier channels defines a barrier channel diameter; and
the barrier channel diameter ranges from 0.1-1 inch (2.5-25 mm).

7. The heat exchanger of claim 1 , further comprising:
a plurality of horizontal vanes, horizontally supporting each of the plurality of first fluid flow assemblies; and
a plurality of vertical vanes, vertically supporting each of the plurality of first fluid flow assemblies;
wherein:
each of the plurality of horizontal vanes defines a horizontal vane thickness;
the horizontal vane thickness ranges from 0.008-0.02 inch (0.2-0.5 mm);
each of the plurality of vertical vanes defines a vertical vane thickness; and
the vertical vane thickness ranges from 0.008-0.02 inch (0.2-0.5 mm).

8. The heat exchanger of claim 1 , wherein:
each of the plurality of first fluid flow assemblies comprises four or more barrier channel vanes;
each of the four or more barrier channel vanes in each of the plurality of first fluid flow assemblies defines a barrier channel vane thickness; and
the barrier channel vane thickness ranges from 0.008-0.02 inch (0.2-0.5 mm).

9. The heat exchanger of claim 1 , wherein each of the plurality of barrier channels comprises a cross-sectional shape that is selected from the group consisting of square, diamond, triangular, pentagonal, hexagonal, octagonal, and oval.

10. The heat exchanger of claim 1 , wherein the heat exchanger core comprises one or more nickel, aluminum, titanium, copper, iron, cobalt, and alloys thereof.

11. The heat exchanger of claim 1 , wherein:
each of the plurality of barrier channels comprises an elliptical cross-sectional shape, defining a major axis and a minor axis;
the major axis defines a major axis length;
the minor axis defines a minor axis length; and
a ratio of the major axis length to the minor axis length ranges from 1 to 2.5.

12. The heat exchanger of claim 11 , wherein:
the major axis is oriented vertically; and
the ratio of the major axis length to the minor axis length ranges from 1.1-1.6.

13. The heat exchanger of claim 1 , wherein:
the inlet transition region defines a vertical transition angle;
the vertical transition angle ranges from 4-40 degrees;
the inlet transition region defines a barrier channel transition angle; and
the barrier channel transition angle ranges from 2-45 degrees.

14. The heat exchanger of claim 1 , wherein:
the outlet transition region defines a vertical transition angle;
the vertical transition angle ranges from 4-40 degrees;
the outlet transition region defines a barrier channel transition angle; and
the barrier channel transition angle ranges from 2-45 degrees.

15. The heat exchanger of claim 13 , wherein:
the vertical transition angle ranges from 12-18 degrees; and
the barrier channel transition angle ranges from 12-18 degrees.

16. The heat exchanger of claim 1 , further comprising a plurality of leakage passages, each of the plurality of leakage passages disposed on an associated plenum vane, thereby fluidly connecting two or more barrier passages.

17. The heat exchanger of claim 16 , further comprisi

Assignees

• Hamilton Sundstrand Corp

Inventors

• Streeter James
• Zager Michael

Classifications

• B22F10/28

  Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] · CPC title

• F28D7/16

  the conduits being arranged in parallel spaced relation ({F28D7/0008 - F28D7/0058 take precedence}; F28D7/02 - F28D7/10 take precedence) · CPC title

• F28F1/02

  Tubular elements of cross-section which is non-circular (F28F1/08, F28F1/10 take precedence) · CPC title

• F28F2265/16

  for preventing leakage · CPC title

• F28F7/02 Primary

  Blocks traversed by passages for heat-exchange media {(F28D7/0008 takes precedence)} · CPC title