Heat exchanger fractal splitter

Patent metadata

Field	Value
Publication number	US-2020309459-A1
Application number	US-201916371392-A
Country	US
Kind code	A1
Filing date	Apr 1, 2019
Priority date	Apr 1, 2019
Publication date	Oct 1, 2020
Grant date	—

Abstract

A flow manifold for a heat exchanger core includes a number of fractal flow splitters arranged in a grid pattern of layers each fluidly connected to a corresponding first circuit layer, a flow plenum having a number of flow channels that are fluidly connected to an associated fractal flow splitter, one or more flow dividing vanes located in each flow channel thereby dividing the associated flow channel into two or more sub-channels, and an outer manifold surrounding the fractal flow splitters and configured to direct a first circuit flow into or out of the heat exchanger core. Each fractal flow splitter has an open end and a plenum end, and provides a transition from the open end to the flow plenum.

First claim

1 . A flow manifold for a heat exchanger core, the heat exchanger core comprising alternating first circuit layers and second circuit layers, the flow manifold comprising:
a plurality of fractal flow splitters arranged in a grid pattern that comprises a plurality of vertical layers, each of the plurality of vertical layers fluidly connected to a corresponding first circuit layer, wherein two or more of the plurality of fractal flow splitters are in each vertical layer; a plurality of flow channels, each flow channel being fluidly connected to an associated fractal flow splitter; a plurality of flow dividing vanes, each disposed within a flow channel and configured to divide the associated flow channel into two or more sub-channels; and an outer manifold surrounding the plurality of fractal flow splitters and configured to direct a first circuit flow into, or out of, the flow manifold; wherein:
each of the fractal flow splitters defines an open end and a plenum end, and is configured to provide a transition from the open end to the flow manifold; and
each of the fractal flow splitters is configured to direct a portion of the first circuit flow toward, or away from, one or more of the flow dividing vanes, thereby directing flow into, or away from, the two or more sub-channels.

2 . The flow manifold of claim 1 , wherein:
the heat exchanger core defines a first circuit flow axis; the flow manifold defines a manifold flow axis; the flow manifold changes a direction of the first circuit flow from the manifold flow axis to the first circuit flow axis by an angle that ranges from 0-120 deg.

3 . The flow manifold of claim 2 , wherein the flow manifold changes the direction of the first circuit flow from the manifold flow axis to the first circuit flow axis by an angle that is about 90 deg.

4 . The flow manifold of claim 1 , wherein:
two adjacent first circuit layers define a vertical spacing; and the vertical spacing ranges from 0.075-0.5 inch (1.9-13 mm).

5 . The flow manifold of claim 4 , wherein the vertical spacing ranges from 0.2-0.3 inch (5-7.5 mm).

6 . The flow manifold of claim 1 , wherein:
the flow channel defines a flow channel width; and the flow channel width ranges between 0.03-0.5 inch (0.8-13 mm).

7 . The flow manifold of claim 6 , wherein the flow channel width ranges from 0.08-0.125 inch (2-3.2 mm).

8 . The flow manifold of claim 1 , wherein:
the fractal flow splitter open end defines an outside diameter (OD); and the outside diameter ranges from 0.04-0.5 inch (1-13 mm).

9 . The flow manifold of claim 8 , wherein the outside diameter ranges from 0.06-0.1 inch (1.5-2.5 mm).

10 . The flow manifold of claim 1 , wherein:
the flow dividing vane defines a vane thickness; and the vane thickness ranges from 0.003-0.2 inch (0.08-5 mm).

11 . The flow manifold of claim 1 , comprising one or more materials selected from the group consisting of: nickel, aluminum, titanium, copper, iron, cobalt, and alloys thereof.

12 . The flow manifold of claim 1 , wherein:
the fractal flow splitter defines a flow splitter length; the flow splitter length ranges from 0.03-0.5 inch (0.8-13 mm) the flow dividing vane at least partially enters the corresponding fractal flow splitter, defining an entrance length; a ratio of the entrance length to the flow splitter length defines a protrusion ratio; and the protrusion ratio ranges from 10-80%.

13 . The flow manifold of claim 12 , wherein the protrusion ratio ranges from 30-60%.

14 . The flow manifold of claim 1 , wherein:
the heat exchanger core comprises a plurality of core channels; each of the plurality of core channels has a sinuous shape defining a peak-to-peak amplitude and a wavelength; and a ratio of the peak-to-peak amplitude to wavelength ranges from 0.05-0.3.

15 . A heat exchanger, comprising at least one of the flow manifolds of claim 1 .

16 . A method of manufacturing a flow manifold for a heat exchanger core, the heat exchanger core comprising alternating first circuit layers and second circuit layers, the method comprising the steps of:
forming the flow manifold comprising:
a plurality of flow channels, each fluidly connected to an associated fractal flow splitter; and
a plurality of flow dividing vanes, each disposed within a flow channel and configured to divide the associated flow channel into two or more sub-channels;
forming a plurality of fractal flow splitters arranged in a grid pattern comprising a plurality of vertical layers, each fractal flow splitter attached to an associated flow channel; and forming an outer manifold surrounding the plurality of fractal flow splitters; wherein:
each of the plurality of fractal flow splitters is metallurgically joined to an associated flow channel; and
the outer manifold is metallurgically joined to the heat exchanger core.

17 . The method of claim 16 , wherein:
the heat exchanger core defines a first circuit flow axis; the flow manifold defines a manifold flow axis; the flow manifold changes a direction of the first circuit flow from the manifold flow axis to the first circuit flow axis by an angle that ranges from 0-120 deg.

18 . The method of claim 16 , wherein the flow manifold comprises one or more materials selected from the group consisting of: nickel, aluminum, titanium, copper, iron, cobalt, and alloys thereof.

19 . The method of claim 16 , wherein:
the fractal flow splitter defines a flow splitter length; the flow splitter length ranges from 0.03-0.5 inch (0.8-13 mm); the flow dividing vane at least partially enters the corresponding fractal flow splitter, defining an entrance length; a ratio of the entrance length to the flow splitter length defines a protrusion ratio; and the protrusion ratio ranges from 10-80%.

20 . The method of claim 19 , wherein the protrusion ratio ranges from 30-60%.

Assignees

• Hamilton Sundstrand Corp

Inventors

• Streeter James

Classifications

• F28D1/0246 Primary

  heat-exchange elements having several adjacent conduits forming a whole, e.g. blocks · CPC title

• F28F7/02 Primary

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

• B22F10/28

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

• B22F2999/00

  Aspects linked to processes or compositions used in powder metallurgy · CPC title

• Y02P10/25

  Process efficiency · CPC title