EP3653984A2 - Flexible verteilerstruktur für plattenrippenwärmetauscher - Google Patents

Flexible verteilerstruktur für plattenrippenwärmetauscher Download PDF

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Publication number
EP3653984A2
EP3653984A2 EP19208360.8A EP19208360A EP3653984A2 EP 3653984 A2 EP3653984 A2 EP 3653984A2 EP 19208360 A EP19208360 A EP 19208360A EP 3653984 A2 EP3653984 A2 EP 3653984A2
Authority
EP
European Patent Office
Prior art keywords
manifold
vertical
flexible manifold
individual layers
heat exchanger
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP19208360.8A
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English (en)
French (fr)
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EP3653984B1 (de
EP3653984A3 (de
Inventor
James Streeter
Frank Z. Feng
Matthew William Miller
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Hamilton Sundstrand Corp
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Hamilton Sundstrand Corp
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Filing date
Publication date
Priority claimed from US16/193,723 external-priority patent/US10801790B2/en
Application filed by Hamilton Sundstrand Corp filed Critical Hamilton Sundstrand Corp
Publication of EP3653984A2 publication Critical patent/EP3653984A2/de
Publication of EP3653984A3 publication Critical patent/EP3653984A3/de
Application granted granted Critical
Publication of EP3653984B1 publication Critical patent/EP3653984B1/de
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
    • F28F9/02—Header boxes; End plates
    • F28F9/026—Header boxes; End plates with static flow control means, e.g. with means for uniformly distributing heat exchange media into conduits
    • F28F9/0265—Header boxes; End plates with static flow control means, e.g. with means for uniformly distributing heat exchange media into conduits by using guiding means or impingement means inside the header box
    • F28F9/0268—Header boxes; End plates with static flow control means, e.g. with means for uniformly distributing heat exchange media into conduits by using guiding means or impingement means inside the header box in the form of multiple deflectors for channeling the heat exchange medium
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
    • F28D9/00—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall
    • F28D9/0062—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits for one heat-exchange medium being formed by spaced plates with inserted elements
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
    • F28F9/02—Header boxes; End plates
    • F28F9/0202—Header boxes having their inner space divided by partitions
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
    • F28F9/02—Header boxes; End plates
    • F28F9/026—Header boxes; End plates with static flow control means, e.g. with means for uniformly distributing heat exchange media into conduits
    • F28F9/027—Header boxes; End plates with static flow control means, e.g. with means for uniformly distributing heat exchange media into conduits in the form of distribution pipes
    • F28F9/0275—Header boxes; End plates with static flow control means, e.g. with means for uniformly distributing heat exchange media into conduits in the form of distribution pipes with multiple branch pipes
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
    • F28D21/00—Heat-exchange apparatus not covered by any of the groups F28D1/00 - F28D20/00
    • F28D2021/0019—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for
    • F28D2021/0021—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for for aircrafts or cosmonautics
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
    • F28F9/02—Header boxes; End plates
    • F28F2009/0285—Other particular headers or end plates
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F2255/00—Heat exchanger elements made of materials having special features or resulting from particular manufacturing processes
    • F28F2255/02—Flexible elements
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F2255/00—Heat exchanger elements made of materials having special features or resulting from particular manufacturing processes
    • F28F2255/14—Heat exchanger elements made of materials having special features or resulting from particular manufacturing processes molded
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F2255/00—Heat exchanger elements made of materials having special features or resulting from particular manufacturing processes
    • F28F2255/16—Heat exchanger elements made of materials having special features or resulting from particular manufacturing processes extruded
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F2265/00—Safety or protection arrangements; Arrangements for preventing malfunction
    • F28F2265/26—Safety or protection arrangements; Arrangements for preventing malfunction for allowing differential expansion between elements
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F2265/00—Safety or protection arrangements; Arrangements for preventing malfunction
    • F28F2265/28—Safety or protection arrangements; Arrangements for preventing malfunction for preventing noise
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F2265/00—Safety or protection arrangements; Arrangements for preventing malfunction
    • F28F2265/30—Safety or protection arrangements; Arrangements for preventing malfunction for preventing vibrations
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F2275/00—Fastening; Joining
    • F28F2275/04—Fastening; Joining by brazing
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F2275/00—Fastening; Joining
    • F28F2275/06—Fastening; Joining by welding

Definitions

  • the present disclosure relates to heat exchangers, and more particularly, to a plate-fin heat exchanger manifold design that improves the thermal robustness of the plate-fin heat exchanger.
  • Plate-fin heat exchangers are well known in the aviation arts and in other industries for providing a compact, low-weight, and highly-effective means of exchanging heat from a hot fluid to a cold fluid. Heat exchangers that operate at elevated temperatures, such as those in modern aircraft engines, often have short service lives due to high steady state and cyclic thermal stresses.
  • Inlet and exit manifolds are typically pressure vessels that are welded or bolted at only the exterior perimeter to a heat exchanger core or matrix. Pressure requirements dictate the thickness of these manifolds, usually resulting in a relatively thick header attached to a thin core matrix. This mismatch in thickness and mass, while acceptable for pressure loads, conflicts with the goal of avoiding geometric, stiffness, mass, and material discontinuities to limit thermal stress.
  • a flexible manifold adapted for use on a plate-fin heat exchanger core includes a plurality of individual layers, each individual layer defining a lower floor, an upper floor, and two side walls.
  • Each of the plurality of individual layers is adapted to channel a flow of a medium therethrough
  • each of the plurality of individual layers includes a plurality of vertical members, each of the plurality of vertical members extends vertically from the lower floor to the upper floor of the respective individual layer, and each of the plurality of vertical members is configured to provide structural support for the respective individual layer.
  • a method of additively manufacturing a first flexible manifold for a heat exchanger comprising the steps of additively building a housing for the first flexible manifold, additively building a plurality of horizontal guide vanes defining a plurality of individual layers for a medium within the housing, and additively building a plurality of vertical members within each of the plurality of individual layers.
  • Each of the plurality of individual layers is adapted to channel a flow of the medium therethrough, each of the plurality of vertical members extends vertically from the lower floor to the upper floor of the respective individual layer, and each of the plurality of vertical members is configured to provide structural support for the respective individual layer.
  • FIG. 1A is a perspective view of a plate-fin heat exchanger core showing the hot layer inlet and outlet manifolds. Shown in FIG. 1A are heat exchanger 10, heat exchanger core 12, first hot manifold 14, second hot manifold 16, hot inlet 40, and hot outlet 42.
  • Heat exchanger 10 includes heat exchanger core 12, where heat can be transferred from a hot medium (not shown) to a cold medium (not shown), while separating the hot medium from the cold medium. Accordingly, heat exchanger 10 includes a hot circuit (not shown) and a cold circuit (not shown).
  • the hot and cold mediums can be a fluid, either or both being a liquid, gas, and/or a mixture of liquid and gas.
  • the hot and/or cold mediums can change phase in or near heat exchanger 10.
  • the hot and/or cold mediums can entrain particles. As used in this disclosure, the hot and/or cold mediums can be referred to as fluids.
  • the hot medium can be called a first medium, and the cold medium can be called a second medium. Accordingly, the hot circuit can be called a first circuit, and the cold circuit can be called a second circuit.
  • the hot medium enters first hot manifold 14 at hot inlet 40, flows through heat exchanger core 12, and exits through second hot manifold 16 at hot outlet 42.
  • Heat exchanger 10 can also include a first and second cold manifold (not shown) for directing the cold circuit.
  • Heat exchanger 10 depicted in FIG. 1A is a cross-flow heat exchanger, because flow through the hot flow circuit is generally across flow through the cold flow circuit (i.e., the direction of hot flow through the heat exchanger core is generally perpendicular to the direction of cold flow through the heat exchanger core).
  • the flow configuration can be different in other embodiments.
  • more than one hot inlet 40 and/or hot outlet 42 can exist.
  • FIG. 1B is a side view of the plate-fin heat exchanger core of FIG. 1A . Shown is FIG. 1B are heat exchanger 10, heat exchanger core 12, first hot manifold 14, second hot manifold 16, bottom end sheet 20, hot closure bars 22, parting sheets 24, cold fins 26, cold closure bars 28, top end sheet 32, hot layers 34, individual layers 36, cold layers 38, hot inlet 40, hot outlet 42, and metallurgical bonds 50.
  • the hot medium enters first hot manifold 14 at hot inlet 40.
  • the hot medium is directed via individual layers 36 into heat exchanger core hot layers 34, then recombines in second hot manifold 16 and exits via hot outlet 42.
  • Alternating hot layers 34 and cold layers 38 are sandwiched between bottom end sheet 20 and top end sheet 32.
  • Hot fins (not shown) channel the flow of the hot medium with boundaries defined by hot closure bars 22 on either side of each hot layer, and parting sheets 24 on the top and bottom of each layer.
  • cold fins 26 channel the flow of the cold medium with boundaries defined by cold closure bars 28 on either side of each cold layer, and parting sheets 24 on the top and bottom of each layer.
  • Metallurgical bonds 50 join each individual layer 36 to the respective hot closure bars 22 and parting sheets 24 of heat exchanger core 12 at hot inlet 40 and hot outlet 42.
  • Each hot layer 34 includes hot fin 30 (not shown), hot closure bars 22 on the left and right, and parting sheets 24 on the top and bottom.
  • each cold layer 38 includes cold fins 26, cold closure bars 28 on the left and right, and parting sheets 24 on the top and bottom.
  • a particular parting sheet 24 is shared by an adjacent hot layer 34 and cold layer 38.
  • Each individual layer 36 includes side walls (not shown in FIG. 1B ) and individual layer floors (not shown in FIG. 1B ), with the side walls being the outer vertical portions of individual layer 36 and the individual layer floors being the upper and lower horizontal portions of individual layers 36. Therefore, metallurgical bonds 50 exist between the side walls and closure bars 22, and between the individual layer floors and parting sheets 24 on first hot manifold 14 and on the second hot manifold.
  • Metallurgical bonds 50 can be created by one of several metal bonding processes, with non-limiting examples including brazing and welding.
  • First and second hot manifolds 14, 16 can be called flexible manifolds because they are thermally and mechanically compliant, thereby being able to withstand temperature and/or pressure changes and/or transients during all phases of operation of heat exchanger 10.
  • FIG. 2 is a perspective view of a second embodiment of the flexible manifold.
  • FIG. 3A is a quarter cut-away perspective view of the flexible manifold of FIG. 2 .
  • FIG. 3B is an end view of a portion of an individual layer of the flexible manifold shown in FIG. 3A . Shown in FIGS. 2 and 3A - 3B are flexible manifold 114, housing 115, port 124, first end 126, second end 128, horizontal guide vanes 130, vertical guide vanes 132, individual layers 136, discrete manifold flow passages 140, side wall second end region 154, and floor second end region 156.
  • floor second end region 156 refers to both the lower and upper horizontal sections of each individual layer 136, and can also be referred to as "floor”.
  • the terms “vertical” and “horizontal” are relative to a standard upright orientation of the heat exchanger, and they do not necessarily imply these guide vanes have specific orientations relative to gravity or the placement and/or orientation of the heat exchanger. Moreover, these terms do not necessarily require, unless specifically stated, that the vanes are exactly perpendicular to one another at some or all points. Accordingly, horizontal guide vanes 130 can be called first guide vanes, and vertical guide vanes 132 can be called second guide vanes.
  • a plurality of horizontal guide vanes 130 extending at least part of a distance from the first end 126 to the second end 128 of flexible manifold 114, or vice versa, define individual layers 136 for at least one medium (e.g., the hot medium in FIGS. 1A - 1B ).
  • a plurality of vertical guide vanes 132 formed at a nonzero angle to horizontal guide vanes 130, can divide ones of the individual layers 136 into a plurality of first discrete manifold flow passages 140 extending at least part of a distance from the first end 126 to the second end 128 of flexible manifold 114, or vice versa.
  • vertical guide vanes 132 can make an angle that is near 90 deg. to horizontal guide vanes 130. Direction of flow would depend on whether flexible manifold 114 is serving as an inlet manifold or an outlet manifold.
  • Individual layers 136 of flexible manifold 114 can be formed as gradual transitions (i.e., continuous, homogeneous transitions) from first end 126 to second end 128 to reduce or eliminate discontinuities that otherwise in conventional designs can cause high stress to the heat exchanger core (not shown), which can lead to an abbreviated service life. Rather, in the present design, the plurality of horizontal vanes 130 and thus individual layers 136 are cantilevered and flexible to allow for elastic deformation from media flowing through the manifold passages.
  • first end 126 can include an opening or port 124 of size A (sized for coupling to a duct, pipe, or the like to receive the first medium 120) that is smaller than a size B of second end 128 at a manifold/core interface (e.g., heat exchanger core 12 in FIGS. 1A - 1B ).
  • Size A can be a diameter of port 124.
  • Size B can be a height of an opening at second end 128.
  • Size B can also correspond to the cumulative area of the opening at second end 128.
  • Depicted in FIG. 3B is a portion of individual layer 136 as viewed from second end 128 showing side wall second end region 154 and floor second end region 156.
  • side wall second end region 154 can be referred to as the sidewalls
  • floor second end regions 156 can be referred to as the floors.
  • floor refers to both the upper and lower floor second end regions 156 of individual layer 136.
  • Side wall second end region 154 has thickness E
  • floor second end region 156 has thickness F, as shown in FIG. 3B .
  • Each individual layer 136 includes side walls 154 and individual layer floors 156, with side walls 154 being the outer vertical portions of individual layer 136 and individual layer floors 156 being the upper and lower horizontal portions of individual layers 136.
  • floor refers to both the lower and upper horizontal sections of each individual layer 136.
  • each individual layer 136 can be said to have a lower floor and an upper floor.
  • Flexible manifold 114 can be formed by additive manufacturing, hybrid additive subtractive manufacturing, subtractive manufacturing, and/or casting, for example.
  • Embodiments of flexible manifolds 114 described herein can leverage additive manufacturing or any other manufacturing method or methods (e.g., casting) that allows one to construct continuous, homogeneous transitions between the heat exchanger core 12 (not shown) and one or more flexible manifolds 114.
  • Additive manufacturing is also useful in building and tailoring vertical guide vanes 132 within flexible manifolds 114.
  • a method of the present disclosure includes forming heat exchanger core 12 for heat exchanger 10 and additively manufacturing a first flexible manifold 114 for heat exchanger 10.
  • Forming a first flexible manifold 114 includes additively building housing 115 for first flexible manifold 114.
  • housing 115 a plurality of horizontal guide vanes 130 are additively built, defining individual layers 136 for the first medium.
  • a plurality of vertical guide vanes 132 can also be additively built, dividing ones of individual layers 136 into a plurality of discrete manifold flow passages 140.
  • laser powder bed fusion can be used as an additive manufacturing process to fabricate flexible manifold 114 from metallic materials.
  • metallic materials that can be used include nickel, aluminum, titanium, copper, iron, cobalt, and all alloys that include these various metals.
  • various alloys of INCONELTM can be used to fabricate flexible manifold 114, with Inconel 625 and Inconel 718 being two exemplary alloy formulations.
  • HAYNESTM 282 can be used in fabricating flexible manifold 114.
  • alloys of aluminum can be used in fabricating to flexible manifold 114.
  • an alloy of aluminum known as AlSi10Mg can be used in fabricating flexible manifold 114. All materials that include metals, metal oxides, and alloys thereof in fabricating flexible manifold 114 are within the scope of the present disclosure.
  • Vertical guide vanes 132 extend the interior vertical dimension of any particular individual layer 136, contacting both the lower and upper horizontal sections of each individual layer 136 (i.e., both floor second end region 156, or both the "lower floor” and the "upper floor”).
  • vertical guide vanes 132 are fabricated during the fabrication of individual layers 136 of flexible manifold 114, being a material that is homogeneous with individual layers 136. Accordingly, vertical guide vanes 132 help provide structural support for individual layers 136, with structural support being provided under both static and dynamic conditions.
  • flexible manifold 114 can be used in an application where the medium has a pressure as high as 1,000 psi (6,895 KPa).
  • vertical guide vanes 132 can assist in limiting or preventing individual layers 136 from deforming under the working pressure of the medium, thereby enhancing the mechanical compliancy of flexible manifold 114. Accordingly, in some embodiments, vertical guide vanes 132 can be under tensile load (i.e., vertical tensile stress in the orientation depicted in FIG. 3A ). Therefore, in some embodiments, vertical guide vanes 132 provide internal structural support to individual layers 136 while also guiding the flow of a fluid (i.e., medium) through individual layers 136. Vertical guide vanes 132 can also be called vertical members because vertical guide vanes 132 are oriented vertically (with reference to the orientation illustrated in FIG. 3A ).
  • FIG. 4 is a top cross-sectional view taken at cut-line 4-4 of layer 136 of flexible manifold 114 shown in FIG. 3 . Shown in FIG. 4 are first end 126, second end 128, horizontal guide vane 130, vertical guide vanes 132, individual layer 136, discrete manifold flow passage 140, side wall 150, side wall first end region 152, and side wall second end region 154.
  • the medium flowing through individual layer 136 is contained by horizontal guide vanes 130 which form the top and bottom pressure boundaries of individual layer 136, and by side walls 150 which form the side pressure boundaries of individual layer 136.
  • Vertical guide vanes 132 direct the flow through individual layer 136, thereby forming discrete manifold flow passages 140.
  • Each side wall 150 has side wall first end region 152 and side wall second end region 154.
  • the thickness of side wall 150 generally tapers from a greater thickness at side wall first end region 152 (corresponding to first end 126) to a smaller thickness at side wall second end region 154 (corresponding to second end 128).
  • side wall second end region 154 has second end side wall thickness E as shown in FIG. 4 .
  • flexible manifold 114 can be an inlet manifold, whereby the flow of a medium can enter individual layer at first end 126 and exit at second end 128 where it can enter a heat exchanger core as described with regard to FIGS. 2-3 .
  • flexible manifold 114 can be an outlet manifold, with medium flow occurring in the opposite direction as described.
  • Vertical guide vanes 132 shown in FIG. 3A are depicted as continuous vertical structures that extend at least part of a distance from the first end 126 to the second end 128 of flexible manifold 114.
  • Vertical guide vanes 132 can be referred to as vertical members, and several different embodiments of the vertical members are within the scope of the present disclosure, as will be described later in FIGS. 5B - 5D . Accordingly, for illustration clarity, simplified drawings can be used to illustrate the detail of these various embodiments.
  • FIG. 5A is a simplified top cross-sectional view of individual layer 136 shown in FIG. 4 .
  • the numbering of features in FIG. 5A , and the description thereof, is the same as provided above with regard to FIG. 4 .
  • Second end side wall thickness E, shown in FIG. 4 is labeled as E1 in FIG. 5A .
  • E1 Second end side wall thickness
  • the number of vertical guide vanes 132 shown in FIG. 5A is limited in order to illustrate the detail of vertical guide vanes 132. In various embodiments, practically any number of vertical guide vanes 132 can be included in each individual layer 136.
  • FIG. 5B is a top cross-sectional view of a second embodiment of layer 136 of flexible manifold 114 shown in FIG. 3 .
  • the feature numbering in FIG. 5B is 100 higher than that in FIG. 5A .
  • Shown in FIG. 5B are first end 226, second end 228, horizontal guide vane 230, vertical columns 232, individual layer 236, discrete manifold flow passage 240, side wall 250, side wall first end region 252, and side wall second end region 254.
  • the medium flowing through individual layer 236 is contained by horizontal guide vanes 230 which form the top and bottom pressure boundaries of individual layer 236, and by side walls 250 which form the side pressure boundaries of individual layer 236.
  • Each side wall 250 has side wall first end region 252 and side wall second end region 254.
  • the thickness of side wall 250 generally tapers from a greater thickness at side wall first end region 252 (corresponding to first end 226) to a smaller thickness at side wall second end region 254 (corresponding to second end 228).
  • side wall 250 has second end side wall thickness E2 as shown in FIG. 5B .
  • second end side wall thickness E2 can be specified to be similar to the thickness of hot closure bars 22.
  • vertical columns 232 connect from the lower horizontal guide vane 230 to the upper guide vane 230 in each individual layer 236, thereby helping provide structural support for individual layers 236. In the illustrated embodiment, flow can occur in either direction from first end 226 to second end 228, or vice versa. Vertical columns 232 can also be referred to as vertical members.
  • FIG. 5C is a top cross-sectional view of a third embodiment of layer 136 of flexible manifold 114 shown in FIG. 3 .
  • the feature numbering in FIG. 5C is 200 higher than that in FIG. 5A .
  • Shown in FIG. 5C are first end 326, second end 328, horizontal guide vane 330, vertical columns 332, individual layer 336, discrete manifold flow passage 340, side wall 350, side wall first end region 352, and side wall second end region 354.
  • the description of individual layer 336 is substantially the same as that of individual layer 236 in regard to FIG. 5B .
  • second end side wall thickness E3 can be specified to be similar to the thickness of hot closure bars 22.
  • the arrangement of vertical columns 332 is in a different pattern from that shown in FIG. 5B . Accordingly, a greater degree of mixing can occur between discrete manifold flow passages 340 than could occur for the pattern shown in FIG. 5B . In the embodiment shown in FIG. 4C , flow can occur in either direction from first end 326 to second end 328, or vice versa.
  • the exemplary patterns of vertical columns 232, 332 shown in FIGS. 5B - 5C are only two of a limitless number of possibilities that can exist in other embodiments. It is to be appreciated a number of vertical members that is much greater than that depicted in the simplified illustrations of FIGS. 5B - 5C can be used to create other arrangement patterns of vertical members.
  • FIG. 5D is a top cross-sectional view of a fourth embodiment of layer 136 of flexible manifold 114 shown in FIG. 3 .
  • the feature numbering in FIG. 5D is 300 higher than that in FIG. 5A
  • Shown in FIG. 5D are first end 426, second end 428, horizontal guide vane 430, vertical hydrofoil columns 432, individual layer 436, discrete manifold flow passage 440, side wall 450, side wall first end region 452, and side wall second end region 454.
  • the description of individual layer 436 is substantially the same as that of individual layer 236 in regard to FIG. 5B .
  • second end side wall thickness E4 can be specified to be similar to the thickness of hot closure bars 22.
  • vertical hydrofoil columns 432 can further assist in directing and/or stabilizing the flow through individual layer 436 as compared to the embodiment shown in FIG. 4B .
  • the cross-sectional shape of vertical hydrofoil columns 432 can reduce the resistance to flow of the medium passing through individual layer 436.
  • vertical hydrofoil columns 432 can be used to reduce the head loss of fluid flowing through individual layer 136 as compared to other designs.
  • hydrofoil refers to a structural shape that can present a reduced resistance to flow as compared to some other structural shapes, without implying that the flowing medium be water, or even a liquid.
  • vertical hydrofoil columns 432 can be configured for the flow of air, or any other gas.
  • the medium that flows around vertical hydrofoil columns 432 can be liquid, gaseous, or any mixture of liquid and/or gas.
  • hydrofoil and “airfoil” can be used interchangeably.
  • the size and shape of vertical hydrofoil columns 432 can be selected to suit the particular embodiment of individual layer 436 with regard to a particular fluid (i.e., medium), with non-limiting examples of various fluid parameters that can be considered including the velocity, density, temperature, compressibility, and/or viscosity of the medium.
  • a particular fluid i.e., medium
  • various fluid parameters that can be considered including the velocity, density, temperature, compressibility, and/or viscosity of the medium.
  • Those who are skilled in the fluid dynamics art are familiar with hydrofoil and airfoil designs.
  • all vertical hydrofoil columns 432 are depicted as having approximately the same size, cross-sectional shape, and spacing from each other.
  • vertical hydrofoil columns 432 can have different sizes, cross-sectional shapes, and/or spacing from others throughout individual layer 436.
  • similar differences can exist from one individual later 436 to another throughout flexible manifold 114.
  • each side wall 450 has side wall first end region 452 and side wall second end region 454.
  • the thickness of side wall 450 generally tapers from a greater thickness at side wall first end region 452 (corresponding to first end 426) to a smaller thickness at side wall second end region 454 (corresponding to second end 428).
  • side wall 450 has second end side wall thickness E4 as shown in FIG. 5D .
  • flow can generally occur in the direction from first end 426 to second end 428, as shown in FIG. 5D , because the hydrofoil shape of vertical hydrofoil columns 432 is generally optimized in the direction shown. However, in some other embodiments, flow can occur in the direction from second end 428 to first end 426.
  • Vertical hydrofoil columns 432 can also be referred to as vertical members.
  • FIGS. 5A - 5D The size, cross-sectional shape, spacing, and arrangement pattern of vertical members depicted in FIGS. 5A - 5D are exemplary, with differences to any of these parameters being within the scope of the present disclosure.
  • vertical guide vanes 132 shown in FIG. 5A
  • vertical columns 232, 332 shown in FIGS. 5B -5C
  • vertical hydrofoil columns 432 shown in FIG. 5D .
  • This can be referred to as the vertical member configuration.
  • the vertical member configuration can differ between various individual layers 136 in a particular flexible manifold 114.
  • the vertical member configuration throughout individual layers 136 in a particular flexible manifold 114 can be different between flexible manifold being used as an inlet manifold and an outlet manifold, for example, if there are appreciable changes in the fluid properties of a medium as it flows from an inlet manifold to an outlet manifold.
  • FIG. 6A is a side cross-sectional view taken at cut line 6A - 6A in FIG. 5A showing several layers of the flexible manifold shown in FIG. 5A .
  • Shown in FIG. 6A are first end 126, second end 128, individual layers group 138, vertical guide vanes 132, individual layers 136, discrete manifold flow passages 140, individual layer floors 160, thick regions 162, and thin regions 164.
  • the description of individual layers 136 are substantially the same as provided above with regard to FIG. 5A .
  • horizontal guide vanes 130 in FIG. 5A are shown as individual layer floors 160 to help show the horizontal pressure boundaries of individual layers 136.
  • Individual layer floors 160 emerge from thick region 162 and taper in thickness near thin region 164 situated at second end 128.
  • Individual layer floors 160 have floor thickness F1 at second end 128, as shown in FIG. 6A .
  • floor thickness F1 can be specified to be similar to the thickness of parting sheet 24 as shown in FIG. 1B .
  • individual floor layers 160 are metallurgically joined to parting sheets 24, thereby partially joining flexible manifold 114 (shown in FIGS. 2 and 3A ) to a heat exchanger core. Accordingly, by providing floor thickness F1 similar to the thickness of parting sheet 24, the mechanical and/or thermal flexibility of flexible manifold 114 can be enhanced. In other embodiments, floor thickness F1 can be greater than or less than the thickness of parting sheet 24.
  • vertical guide vane 132 spans the interior height of each individual layer 136, from one individual floor layer 160 to the next.
  • vertical guide vanes 132 are rectangular in cross-sectional shape, having straight vertical edges at both the edge nearest second end 128 and away from second end 128.
  • vertical guide vanes 132 can have edges that are different from that depicted in FIG. 6A .
  • vertical edges having a geometry that is different from straight can be used for one or more reasons, as will be described later in FIG. 6B .
  • FIG. 6B is a side cross-sectional view showing several layers of a second embodiment of the flexible manifold shown in FIG. 5B , taken at the same cut line as in FIG. 6A . Shown in FIG. 6B are first end 526, second end 528, individual layers group 538, vertical guide vanes 532, end radii 534, individual layers 536, discrete manifold flow passages 540, individual layer floors 560, thick regions 562, and thin regions 564. The description of individual layers 536 are substantially the same as provided above with regard to FIG. 6A . In the embodiment shown in FIG. 6B , vertical guide vanes 532 have end radius 534 at both the edge nearest second end 528 and away from second end 528.
  • end radii 534 on vertical guide vanes 530 can be achieved in the design of end radii 534 on vertical guide vanes 530, with non-limiting examples being to reduce material stress and/or structural vibration in flexible manifold 114, or to reduce flow turbulence of the fluid (i.e., medium) flowing through flexible manifold 114.
  • vertical guide vanes 532 help maintain the structure of each individual layer 536, particularly when the medium within individual layers 536 is at pressure. Accordingly, in some embodiments, vertical guide vanes 532 can be under tensile stress in the vertical direction. Therefore, in these embodiments, end radii 534 help control stress intensification in the regions where vertical guide vanes 532 attach to individual floor layers 560. In other embodiments, end radii 534 can be shapes other than round as shown in FIG. 6B . As used in this disclosure with regard to the shape of vertical guide vanes 532, the term "radius" can be used to describe any curved geometrical shape.
  • non-limiting examples of geometric shapes for end radii 534 can be elliptical or parabolic.
  • one end of vertical guide vanes 532 can have a shape of end radius 534 different from the other end of vertical guide vanes 532.
  • individual floor layers 560 have floor thickness F5, with the value of floor thickness F5 being similar to that of floor thickness F1 described above with regard to FIG. 6A .
  • FIG. 6C is a side cross-sectional view taken at cut line 6C - 6C in FIG. 5B showing several layers of the flexible manifold shown in FIG. 5B . Shown in FIG. 6C are first end 226, second end 228, individual layers group 238, vertical columns 232, individual layers 236, discrete manifold flow passages 240, individual layer floors 260, thick regions 262, and thin regions 264. The description of individual layers 236 are substantially the same as provided above with regard to FIG. 6B . In the embodiment shown in FIG. 6C , vertical columns 232 are shown as cross-sections of vertical columns 232 shown in FIG.5B . Individual layer floors 260 have floor thickness F2 at second end 228, with the value of floor thickness F2 being similar to that of floor thickness F1 described above with regard to FIG. 6A .
  • FIG. 6D is a side cross-sectional view taken at cut line 6D - 6D in FIG. 5D showing several layers of the flexible manifold shown in FIG. 5D . Shown in FIG. 6D are first end 426, second end 428, individual layers group 438, vertical hydrofoil columns 432, 432', individual layers 436, discrete manifold flow passages 440, individual layer floors 460, thick regions 462, and thin regions 464. The description of individual layers 436 are substantially the same as provided above with regard to FIG. 5D . In the embodiment shown in FIG. 6D , vertical hydrofoil columns 432 are shown as cross-sections of vertical hydrofoil columns 432 shown in FIG.5D .
  • Non-cross-sectioned vertical hydrofoil columns 432' are also shown in FIG. 6D .
  • Individual layer floors 460 have floor thickness F4 at second end 428, with the value of floor thickness F4 being similar to that of floor thickness F1 described above with regard to FIG. 6A .
  • heat exchanger 10 can also include a cold circuit in order to function properly in a particular embodiment.
  • a cold fluid i.e., medium
  • heat exchanger 10 can also include one or more cold inlet manifolds and/or cold outlet manifolds (not shown in FIGS. 1A - 1B ).
  • the cold medium can have fluid properties (e.g., velocity, density, temperature, compressibility, and/or viscosity) different from the hot medium.
  • cold inlet manifolds and/or cold outlet manifolds can include vertical members having designs that are different from vertical members in hot inlet manifolds and/or hot outlet manifolds.
  • a flexible manifold adapted for use on a plate-fin heat exchanger core comprising a plurality of individual layers, each individual layer defining a lower floor, an upper floor, and two side walls, wherein: each of the plurality of individual layers is adapted to channel a flow of a medium therethrough; each of the plurality of individual layers includes a plurality of vertical members; each of the plurality of vertical members extends vertically from the lower floor to the upper floor of the respective individual layer; and each of the plurality of vertical members is configured to provide structural support for the respective individual layer.
  • the flexible manifold of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional components:
  • a further embodiment of the foregoing flexible manifold comprising a first end with at least one port adapted to receive or discharge the medium; and a second end distal from the first end, adapted to transfer the medium to or from the plurality of individual layers; wherein: two adjacent horizontal guide vanes define the respective individual layer there between; the plurality of individual layers are configured to be metallurgically joined to respective ones of a plurality of layers of the plate-fin heat exchanger core; and the flexible manifold is configured to be mechanically and thermally compliant.
  • each of the plurality of vertical members is configured to direct a flow of the medium through the respective individual layer.
  • the plate-fin heat exchanger core comprises a plurality of core layers, each core layer including: two parting sheets, each defining a parting sheet thickness; and two closure bars, each defining a closure bar thickness.
  • each side wall has a first end side wall thickness and a first end floor thickness adjacent a first end of the flexible manifold; the first end side wall thickness is equal to the closure bar thickness; and the first end floor thickness is equal to the parting sheet thickness.
  • the vertical members comprise vertical guide vanes dividing each of the plurality of individual layers into a plurality of discrete manifold flow passages extending at least part of a distance from a first end to a second end of the flexible manifold.
  • a further embodiment of the foregoing flexible manifold wherein the vertical columns have a hydrofoil cross section configured to control the flow of the medium through each of the plurality of individual layers.
  • a further embodiment of the foregoing flexible manifold comprising a plate-fin heat exchanger.
  • a method of additively manufacturing a flexible manifold for a heat exchanger comprising the steps of: additively building a housing for the first flexible manifold; within the housing, additively building a plurality of horizontal guide vanes defining a plurality of individual layers for a medium; and additively building a plurality of vertical members within each of the plurality of individual layers; wherein: each of the plurality of individual layers is adapted to channel a flow of the medium therethrough; each of the plurality of vertical members extends vertically from a lower floor to an upper floor of the respective individual layer; and each of the plurality of vertical members is configured to provide structural support for the respective individual layer.
  • the method of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional components:
  • steps of additively building comprise performing laser powder bed fusion.
  • the vertical members comprise vertical guide vanes dividing each of the plurality of individual layers into a plurality of discrete manifold flow passages extending at least part of a distance from a first end to a second end of the flexible manifold.
  • the vertical guide vanes further define at least one end radius configured to reduce material stress in a region of the respective individual layer.
  • the vertical members comprise vertical columns configured to provide structural support for each of the plurality of individual layers.
  • a further embodiment of the foregoing method further comprising the steps of: forming a heat exchanger core, comprising a plurality of individual core layers; and metallurgically joining each of the individual layers to respective ones of the plurality the individual core layers, thereby metallurgically joining the first flexible manifold to the heat exchanger core; wherein the metallurgical joining comprises brazing or welding; thereby making plate-fin heat exchanger.

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Heat-Exchange Devices With Radiators And Conduit Assemblies (AREA)
EP19208360.8A 2018-11-16 2019-11-11 Flexible verteilerstruktur für plattenrippenwärmetauscher Active EP3653984B1 (de)

Applications Claiming Priority (1)

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US16/193,723 US10801790B2 (en) 2018-03-16 2018-11-16 Plate fin heat exchanger flexible manifold structure

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EP3653984A2 true EP3653984A2 (de) 2020-05-20
EP3653984A3 EP3653984A3 (de) 2020-07-29
EP3653984B1 EP3653984B1 (de) 2023-01-25

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Publication number Priority date Publication date Assignee Title
US3885936A (en) * 1972-03-01 1975-05-27 Lund Basil Gilbert Alfred Heat exchangers
NO321805B1 (no) * 2001-10-19 2006-07-03 Norsk Hydro As Fremgangsmate og anordning for a lede to gasser inn og ut av kanalene i en flerkanals monolittenhet.
US9297261B2 (en) * 2012-03-07 2016-03-29 United Technologies Corporation Airfoil with improved internal cooling channel pedestals
US20170146305A1 (en) * 2015-11-24 2017-05-25 Hamilton Sundstrand Corporation Header for heat exchanger
US20170211888A1 (en) * 2016-01-21 2017-07-27 Hamilton Sundstrand Corporation Heat exchanger with center manifold and thermal separator
GB2560946A (en) * 2017-03-29 2018-10-03 Hieta Tech Limited Heat exchanger
US10443959B2 (en) * 2018-03-16 2019-10-15 Hamilton Sundstrand Corporation Integral heat exchanger manifold guide vanes and supports

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EP3653984A3 (de) 2020-07-29

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