The present disclosure relates to a heat exchanger. More particularly, the present disclosure relates to a curved heat exchanger for use in a gas turbine engine.
In some portions of gas turbine engines, available space for mounting certain hardware elements is limited to curved, annular regions of space. When placed in these annular spaces, the use of existing rectangular shaped pieces of hardware limits the size and efficiency of the hardware.
A heat exchanger assembly includes first and second annular ducts, first and second airflow pathways, and a heat exchanger with a partially annular shape. The first annular duct forms a fluidic barrier between the first and second airflow pathways. The first airflow pathway is configured to transport a first airflow and is disposed within and formed by the first annular duct. The second annular duct is disposed radially outward from the first annular duct. The second airflow pathway is configured to transport a second airflow and is disposed between and formed by the first and second annular ducts. The heat exchanger includes inner and outer portions. The inner portion is disposed radially inward of the first annular duct and is fluidly connected to the first airflow pathway. The outer portion is disposed between the first and second annular ducts and is fluidly connected to the second airflow pathway. The heat exchanger is configured to cool a third airflow with both of the first and second airflows from the first and second airflow pathways.
A method of manufacturing a heat exchanger with cold layers and hot layers includes manipulating each of the cold layers such that each of the cold layers includes a tapered side profile. The cold and hot layers are arranged into an alternating pattern such that each of the hot layers is adjacent to and in contact with at least one of the cold layers. The hot layers and cold layers are brazed together to form a core.
A heat exchanger for an engine with a duct and first and second airflow pathways includes a partially annular curved core, an inner portion fluidly connected to the first airflow pathway, and an outer portion disposed radially outward from the inner portion. The partially annular curved core includes a plurality of hot layers and a plurality of cold layers. Each of the plurality of hot layers is configured to transport a third airflow. The hot and cold layers are arranged in a stack such that each of the plurality of hot layers is adjacent to and in contact with at least one of the cold layers in the stack. Each of the cold layers comprises a taper in a radial direction such that a radially outward end of each of the cold layers is larger than a radially inward end of each of the cold layers along a circumferential direction of the partially annular curved core. The inner portion comprises radially inward halves of the hot and cold layers. The outer portion is fluidly connected to the second airflow pathway and comprises radially outward halves of the hot and cold layers. The heat exchanger is configured to cool the third airflow with airflows from the first and second airflow pathways.
The present summary is provided only by way of example, and not limitation. Other aspects of the present disclosure will be appreciated in view of the entirety of the present disclosure, including the entire text, claims, and accompanying figures.
While the above-identified figures set forth one or more embodiments of the present disclosure, other embodiments are also contemplated, as noted in the discussion. In all cases, this disclosure presents the invention by way of representation and not limitation. It should be understood that numerous other modifications and embodiments can be devised by those skilled in the art, which fall within the scope and spirit of the principles of the invention. The figures may not be drawn to scale, and applications and embodiments of the present invention may include features and components not specifically shown in the drawings.
Heat exchanger 10 is a heat exchanger in the shape of a partial annulus. In one non-limiting embodiment, heat exchanger is a circumferentially stacked counter-flow curved heat exchanger. As will be discussed in
Inner portion 12 is connected to and extends radially inward from outer portion 14 of heat exchanger 10. Outer portion 14 is connected to and extends radially outward from inner portion 12 of heat exchanger 10. Inlet header 16 is mounted onto inner portion 12 of heat exchanger 10. Outlet header 18 is mounted onto outer portion 14 of heat exchanger 10. Outlet 20 extends radially outward from outlet header 18. First airflow AF1 flows into and through inner portion 12 (in a direction from left to right as shown in
In heat exchanger 10 with separate inner portion 12 and outer portion 14, third airflow AF3 goes into heat exchanger 10 and is cooled first by first airflow AF1 passing through inner portion 12 and then by second airflow AF2 passing through outer portion 14. Here, there are two discrete sections (e.g., inner portion 12 and outer portion 14) being cooled by two different and independent flows of cooling air (e.g., first airflow AF1 and second airflow AF2). In existing designs, multiple flows of hot air are cooled by a single flow of cold air. Additionally, first airflow AF1 and second airflow AF2 are configured to cool third airflow AF3 in a parallel relationship as compared to a series relationship in existing heat exchanger assemblies. In one non-limiting embodiment, the temperatures of first airflow AF1 and second airflow AF2 can be different.
Inner duct 22 and outer duct 34 are annular tubes of solid material such as metal. In one non-limiting embodiment, either inner duct 22 or outer duct 34 can be an engine fan case. Radius RID and radius ROD are radii of inner duct 22 and outer duct 34, respectively relative to axial centerline CL. Mounting flange 24 is a curved ribbon of solid material. Assembly 26 is a group of mechanical elements. Inner surface 28 is a curved, radially inward surface of inner portion 12 of heat exchanger 10. Radius RIS is a radius of inner surface 28 measured from axial centerline CL. Outer surface 30 is a curved, radially outward surface of outer portion 14 of heat exchanger 10. Radius ROS is a radius of outer surface 30 measured from axial centerline CL. Cutout 32 is a hole or opening. First airflow pathway 36 is an annular passage configured for the transport of a fluid such as air. Second airflow pathway 38 is an annular or ring-shaped passage configured for the transport of a fluid such as air.
Heat exchanger 10 is disposed in cutout 32 of inner duct 22 and is mounted to inner duct 22 via mounting flange 24. In this non-limiting embodiment, the curvature or curved shape of heat exchanger 10 conforms to and/or is complimentary with the curvature or curved shape of either inner duct 22 or outer duct 34. In another non-limiting embodiment, the curvature or curved shape of inner surface 28 of inner portion 12 conforms to and/or is complimentary with the curvature or curved shape of inner duct 22. In another non-limiting embodiment, the curvature or curved shape of outer surface 30 of outer portion 14 conforms to and/or is complimentary with the curvature or curved shape of outer duct 34. In another non-limiting embodiment, the difference between radius ROS of outer surface 30 and radius ROD of outer duct 34 remains generally constant along a circumference of outer duct 34 (or along a circumference of outer surface 30). In another non-limiting embodiment, the difference between radius RIS of inner surface 28 and radius RID of inner duct 22 remains generally constant along a circumference of inner duct 22 (or along a circumference of inner surface 28).
Inner portion 12 of heat exchanger 10 is disposed in and is in fluid communication with first airflow pathway 36. Outer portion 14 of heat exchanger 10 is disposed in and is in fluid communication with second airflow pathway 38. Inlet header 16 extends partially into a portion of first airflow pathway 36. Inlet header 16 is fluidly connected to a source of hot air. Outlet header 18 extends partially into a portion of second airflow pathway 38. Outlet header 18 is fluidly connected to hot air discharge region of assembly 26. Inner duct 22 is disposed radially inward from outer duct 34. Inner duct 22 forms an outer barrier of first airflow pathway 36 and forms an inner barrier of second airflow pathway 38. In this non-limiting embodiment, radius RID of inner duct 22 is greater than radius RIS of inner surface 28 and is less than both radius ROD of outer duct 34 and radius ROS of outer surface 30.
Mounting flange 24 is connected to and extends axially (and/or circumferentially) from sides of heat exchanger 10. A shape of mounting flange 24 includes a curved ribbon that matches a shape of inner duct 22. For example, a curvature of mounting flange 24 is approximately equal to a curvature of inner duct 22. Mounting flange 24 is mounted to inner duct 22 via mechanical or chemical attachment such as fasteners, adhesives, or welding. In this non-limiting embodiment, mounting flange 24 extends out from heat exchanger 10 on all four sides of heat exchanger 10 (as shown in
Inner surface 28 is disposed along a radially inward surface of inner portion 12 of heat exchanger 10. In this non-limiting embodiment, radius RIS of inner surface 28 is less than radius ROS of outer surface 30, radius ROD of outer duct 34, and radius RID of inner duct 22. Outer surface 30 is disposed along a radially outward surface of outer portion 14 of heat exchanger 10. In this non-limiting embodiment, radius ROS of outer surface 30 is less than radius ROD of outer duct 34 and is greater than radius RIS of inner surface 28 and radius RID of inner duct 22. Cutout 32 is disposed in (e.g., cut out of) a portion of inner duct 22 and is shaped to receive heat exchanger 10. Outer duct 34 surrounds and is disposed radially outward from inner duct 22. Outer duct 34 forms outer barrier of second airflow pathway 38. In this non-limiting embodiment, radius ROD of outer duct 34 is greater than radius RIS of inner surface 28, radius RID of inner duct 16, and radius ROS of outer surface 30.
First airflow pathway 36 is disposed within and travels through inner duct 22. First airflow pathway 36 is in fluid communication with inner portion 12 of heat exchanger 10. Second airflow pathway 38 is a disposed within and travels between inner duct 22 and outer duct 34. Second airflow pathway 38 is in fluid communication with outer portion 14 of heat exchanger 10.
Heat exchanger 10 functions to transfer heat from a hot airflow flowing through heat exchanger 10 to first and second airflow pathways 18 and 20, which in this non-limiting embodiment are both cold airflows that are separate from each other. Inner portion 12 receives a portion of the airflow from first airflow pathway 36. Heat is transferred from the hot airflow in heat exchanger 10 to the portion of the airflow from first airflow pathway 36 passing through inner portion 12. Outer portion 14 receives a portion of the airflow from second airflow pathway 38. Heat is transferred from the hot airflow in heat exchanger 10 to the portion of second airflow pathway 38 passing through outer portion 14.
Inlet header 16 receives hot airflow and transports the hot airflow into inner portion 12 of heat exchanger 10. Outlet header 18 vents out the hot airflow from outer portion 14 from heat exchanger 10 after the hot airflow has flown through both inner and outer portions 12 and 14 of heat exchanger 10. Assembly 26 functions to provide a curved heat exchanger that fits within the design envelope of inner duct 22 and outer duct 34 so as to maximize the amount of space taken up by heat exchanger 10 within assembly 26. Inner duct 22 functions to guide and transport first airflow pathway 36 through inner duct 22. Cutout 32 functions to provide a mounting space for heat exchanger 10. A shape of a boundary of cutout 32 is sized to match a shape of heat exchanger 10 at a portion of heat exchanger next to mounting flange 24. Outer duct 34 functions to guide and transport second airflow pathway 38 through outer duct 34. First airflow pathway 36 functions to provide inner portion 12 of heat exchanger 10 with a first cooling airflow. Second airflow pathway 38 functions to provide outer portion 14 of heat exchanger 10 with a second cooling airflow.
Mounting flange 24 is used to mount heat exchanger 10 to inner duct 22 of assembly 26. In this non-limiting embodiment, mounting flange 24 is mounted onto a radially outward surface on inner duct 22. In other non-limiting embodiments, mounting flange 24 can be mounted onto a radially inward facing surface of inner duct 22. In addition to providing a mounting function, mounting flange 24 also provides additional heat transfer between heat exchanger 10 and second airflow pathway 38 and inner duct 22. Mounting flange 24 is mounted to inner duct 22 via a series of bolts and locking nut plates.
The curved shape of heat exchanger 10 allows heat exchanger 10 to more efficiently use the space between inner duct 22 and outer duct 34 as compared to traditional rectangular heat exchangers. Using curved heat exchanger 10 in assembly 26 allows for the use of space to be maximized due to the shape of heat exchanger 10 matching the contour of the curved shape of outer duct 34 and minimizing a space or gap between outer surface 30 of heat exchanger 10 and outer duct 34. In other words, the curved shape of heat exchanger 10 provides maximum utilization of available space by heat exchanger 10 within assembly 26. By maximizing the amount of space taken up by heat exchanger 10 within the design envelope of assembly 26, a greater amount of space inside of assembly 26 (e.g., between and within inner and outer ducts 22 and 34) is utilized for thermal management as compared to existing designs of rectangular, box, or cubic shaped heat exchangers placed in curved spaces.
Cold layers 42 and hot layers 44 are arranged in an alternating relationship such that every other layer is a cold layer 42, hot layer 44, cold layer 42, . . . etc. Core 40 gets its curved shaped from the fact that each of cold layers 42 is tapered towards the radially inward ends. As core 40 is formed by every other layer of colds fins 42 and hot fins 44, the tapered shape of cold fins 42 creates a slight radially inward curvature of core 40 at each of cold fins 42. The curved shape of core 40 by way of the tapered shape of cold fins 42 allows heat exchanger 10 to have a curved shape conforming to the curvature of inner and outer ducts 22 and 34.
Across hot layer 44, a width, height, and length of hot layer 44 remain consistent. First region 46 is a first region of hot layer 44 designated by fins that are oriented in a generally vertical orientation (as shown in
First region 46 is disposed within a portion of sidewall 58. First region 46 of first fins 48 is connected to and in fluid communication with first opening 60 and with second region 50 of second fins 52. First fins 48 are interconnected to form a single wavy sheet of physical material. First fins 48, second fins 52, and third fins 56 are configured in such a way so as to maximize a surface area of hot layer 44 so as to increase the heat exchanging capabilities of hot layer 44. Second region 50 is disposed within a portion of sidewall 58. Second region 50 of second fins 52 is connected to and in fluid communication with first region 46 of first fins 48 and third region 54 of third fins 56. Second fins 52 are interconnected to form a single wavy sheet of physical material. Third region 54 is disposed within a portion of sidewall 58. Third region 54 of third fins 56 is connected to and in fluid communication with second opening 62 and second region 50 of second fins 52. Third fins 56 are interconnected to form a single wavy sheet of physical material.
Sidewall 58 surrounds portions of first region 46 of first fins 48, second region 50 of second fins 52, and third region 54 of third fins 56. First opening 60 and second opening 62 are formed in portions of sidewall 58. First opening 60 is fluidly connected to first region 46 of first fins 48. Second opening 62 is fluidly connected to third region 54 of third fins 56.
Each of first region 46, second region 50, and third region 54 of fins function to transport a flow of air (e.g., third airflow AF3 from
As will be discussed in relation to other figures, the configuration of hot layer 44 with first, second, and third regions 46, 50, and 54 allows for hot layer 44 with a single flow of hot air to be cooled by two independent flows of cold air by cold layers 42. Cooling of the flow of hot air through hot layer 44 with two independent flows of cold air via cold layers 42 provides increased cooling of the flow of hot air through hot layers 44 as compared to multiple flows of hot air being cooled by a single flow of cold air.
Cold layer 42 is one of cold layers 42 shown as part of core 40 in
First end 66 is a bottom end of cold layer 42 (with the bottom direction as shown in
Fins 64 are interconnected to form a single zig-zag sheet of physical material. Fins 64 are configured in such a way so as to maximize a surface area of cold layer 42 so as to increase the heat exchanging capabilities of cold layer 42. First end 66 is a radially inward end of cold layer 42 relative to the configuration of core 40 as shown in
Fins 64 function to transport a flow or flows of cold air (e.g., first and second airflows AF1 and AF2 shown in
As discussed above with respect to heat exchanger 10 being curved, the curved shape of core 40 due to the tapered side profile of cold layers 42 allows heat exchanger 10 to more efficiently use curved space as compared to traditional rectangular heat exchangers. Using core 40 with cold layers 42 in assembly 26 allows for the use of space to be maximized due to the shape of heat exchanger 10 matching the contour of the curved shape of outer duct 34 and minimizing a space or gap between heat exchanger 10 and outer duct 34. In other words, the curved shape of core 40 due to the tapered side profile of cold layers 42 provides maximum utilization of available space by heat exchanger 10 within assembly 26.
Slots 70 are openings or channels (e.g., redistribution slots) in fins 64 of cold layer 42. Bars 72 are pieces of solid material. Sidewalls 74 are closure bars that contain airflow within cold layer 42. As is shown in
First airflow AF1 passes through inner portion 12 and second airflow AF2 passes through outer portion 14 such that first airflow AF1 and second airflow AF2 remain fluidly separated. First airflow AF1 and second airflow AF2 provide a cooling function with first airflow AF1 and second airflow AF2 in parallel. Slots 70 redistribute or allow a portion of first airflow AF1 to drop behind bars 72 so as to transport a portion of first airflow AF1 to fins 46 that are positioned in axial alignment with bars 72. Without slots 70, fins 46 placed in axial alignment would not receive any of first airflow AF1 because bars 72 would block flow moving in a left to right direction.
Slots 70 enable a portion of first airflow AF1 to pass between bars 72 thereby maximizing the surface area of cold layer 42 that first airflow AF1 passes across. Bars 72 provide a connection point for mounting flanges 24 to connect to cold layer 42 of heat exchanger 10 in order to mount heat exchanger 10 to inner duct 22.
As third airflow AF3 enters into first region 46 of first fins 48 from inlet header 16, third airflow AF3 moves in a generally upward or vertical direction (upwards in
The relative directions of third airflow AF3 through hot layer 44 and of first and second airflows AF1 and AF2 (as shown in
In one non-limiting embodiment, a method of manufacturing heat exchanger 10 with cold layers 42 and hot layers 44 includes manipulating each of cold layers 42 such that each of cold layers 42 includes a tapered side profile. For example, manipulating each of cold layers 42 such that each of cold layers 42 includes a tapered side profile can include forming each of cold layers 42 to include a taper in a radial direction such that a radially outward end of each of cold layers 42 is larger than a radially inward end of each of cold layers 42 along a circumferential direction of core 40. The tapered side profile of each of cold layers 42 can be achieved by running each of cold layers 42 through rollers. An electrical discharge machine process is used to form 70 into each of cold layers 42.
Cold layers 42 and hot layers 44 are arranged into an alternating pattern such that each of hot layers 44 is adjacent to and in contact with at least one of cold layers 42. Cold layers 42 and hot layers 44 are oriented relative to each other such that separate first and second airflows AF1 and AF2 of cold layer 42 are used to cool third airflow AF3 of hot layer 44. Cold layers 42 and hot layers 44 are brazed together to form the curved circumferentially stacked core 40. Mounting flanges 24 are welded onto core 40. Inlet and outlet headers 16 and 18 are also welded onto core 40.
The following are non-exclusive descriptions of possible embodiments of the present invention.
A heat exchanger assembly includes first and second annular ducts, first and second airflow pathways, and a heat exchanger with a partially annular shape. The first annular duct forms a fluidic barrier between the first and second airflow pathways. The first airflow pathway is configured to transport a first airflow and is disposed within and formed by the first annular duct. The second annular duct is disposed radially outward from the first annular duct. The second airflow pathway is configured to transport a second airflow and is disposed between and formed by the first and second annular ducts. The heat exchanger includes inner and outer portions. The inner portion is disposed radially inward of the first annular duct and is fluidly connected to the first airflow pathway. The outer portion is disposed between the first and second annular ducts and is fluidly connected to the second airflow pathway. The heat exchanger is configured to cool a third airflow with both of the first and second airflows from the first and second airflow pathways.
The heat exchanger assembly of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional components.
The heat exchanger can further comprise a first plurality of heat exchanger layers, and/or a second plurality of heat exchanger layers, wherein each layer of the first and second pluralities of heat exchanger layers can extend across the inner portion and/or outer portions, wherein the first and/or second pluralities of heat exchanger layers can be arranged in an alternating pattern such that each of the plurality of first heat exchanger layers can be adjacent to and/or in contact with at least one of the plurality of second heat exchanger layers, wherein each of the second heat exchanger layers can comprise a taper in a radial direction such that a radially outward end of each of the second heat exchanger layers can be larger than a radially inward end of each of the second heat exchanger layers along a circumferential direction.
The first annular duct can include a cutout, wherein a portion of the heat exchanger can be mounted within the cutout.
A flange can extend axially from the heat exchanger, wherein the flange can be mounted to the first annular duct.
The first annular duct can include a first radius, wherein the second annular duct can include a second radius, wherein the heat exchanger can include an outer surface with a third radius, wherein the third radius can be greater than the first radius and/or less than the second radius.
A difference between third radius and the second radius can remain constant along a circumference of the second annular duct.
The heat exchanger can comprise a circumferentially stacked counter-flow curved heat exchanger.
The second plurality of heat exchanger layers can comprise a redistribution slot disposed in each of the second plurality of heat exchanger layers.
A method of manufacturing a heat exchanger with cold layers and hot layers includes manipulating each of the cold layers such that each of the cold layers includes a tapered side profile. The cold and hot layers are arranged into an alternating pattern such that each of the hot layers can be adjacent to and in contact with at least one of the cold layers. The hot layers and cold layers are brazed together to form a core.
The method of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following steps, features, configurations and/or additional components.
Each of the cold layers can be formed to include a taper in a radial direction such that a radially outward end of each of the cold layers can be larger than a radially inward end of each of the cold layers along a circumferential direction of the core.
The hot and cold layers can be oriented relative to each other such that two separate cold airflows of the cold layer can be used to cool a single hot airflow of the hot layer.
The hot and cold layers can be brazed together to form a curved circumferentially stacked core.
A tapered side profile of each of the cold layers can be formed by running each of the cold layers through rollers.
Mounting flanges can be welded onto the core.
Inlet and/or outlet headers can be welded onto the core.
An electrical discharge machine process can be used to form a redistribution slot into the cold layer.
A heat exchanger for an engine with a duct and first and second airflow pathways includes a partially annular curved core, an inner portion fluidly connected to the first airflow pathway, and an outer portion disposed radially outward from the inner portion. The partially annular curved core includes a plurality of hot layers and a plurality of cold layers. Each of the plurality of hot layers is configured to transport a third airflow. The hot and cold layers are arranged in a stack such that each of the plurality of hot layers is adjacent to and in contact with at least one of the cold layers in the stack. Each of the cold layers comprises a taper in a radial direction such that a radially outward end of each of the cold layers is larger than a radially inward end of each of the cold layers along a circumferential direction of the partially annular curved core. The inner portion comprises radially inward halves of the hot and cold layers. The outer portion is fluidly connected to the second airflow pathway and comprises radially outward halves of the hot and cold layers. The heat exchanger is configured to cool the third airflow with airflows from the first and second airflow pathways.
The heat exchanger 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 curvature of the heat exchanger can conform to a curvature of the duct of the engine.
The heat exchanger can comprise a circumferentially stacked counter-flow curved heat exchanger.
A curved flange can extend from the heat exchanger, wherein the curved flange can be configured to mount the heat exchanger to the engine.
While the invention has been described with reference to an exemplary embodiment(s), 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 invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof Therefore, it is intended that the invention not be limited to the particular embodiment(s) disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.
This invention was made with government support under FA8626-16-C-2139 awarded by United States Air Force. The government has certain rights in the invention.
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