Heat exchanger with radially converging manifold

Abstract

A heat exchanger manifold configured to receive or discharge a first fluid includes a primary fluid channel and a plurality of secondary fluid channels. The primary fluid channel includes a fluid port and a first branched region distal to the fluid port. The plurality of secondary fluid channels are fluidly connected to the primary fluid channel at the first branched region. Each of the plurality of secondary fluid channels includes a first end and a second end opposite the first end. Each of the plurality of secondary fluid channels extends radially from the first branched region at the first end and has an equal length from a center of the first branched region to the second end.

Description

BACKGROUND

This disclosure relates generally to heat exchangers, and more specifically to manifolds for heat exchangers with fractal geometry.

Heat exchangers are well known in many industries for providing compact, low-weight, and highly-effective means of exchanging heat from a hot fluid to a cold fluid. Heat exchangers can operate in high temperature environments, such as in modern aircraft engines. Heat exchangers that operate at elevated temperatures can have reduced service lives due to high thermal stress. Thermal stress can be caused by uneven temperature distribution within the heat exchanger or with abutting components, component stiffness and geometry discontinuity, and/or other material properties of the heat exchanger. The interface between an inlet/outlet manifold and the core of a heat exchanger can be subject to the highest thermal stress and the shortest service life.

Additive manufacturing techniques can be utilized to manufacture heat exchangers layer by layer to obtain a variety of complex geometries. Depending on the geometry of the heat exchanger, additional internal or external support structures can be necessary during additive manufacturing to reinforce a build. Often, removal of internal support structures from a heat exchanger is difficult or even impossible, thereby limiting the geometries that can be built successfully.

SUMMARY

In one example, a heat exchanger manifold configured to receive or discharge a first fluid includes a primary fluid channel and a plurality of secondary fluid channels. The primary fluid channel includes a fluid port and a first branched region distal to the fluid port. The plurality of secondary fluid channels are fluidly connected to the primary fluid channel at the first branched region. Each of the plurality of secondary fluid channels includes a first end and a second end opposite the first end. Each of the plurality of secondary fluid channels extends radially from the first branched region at the first end and has an equal length from a center of the first branched region to the second end.

In another example, a heat exchanger includes an inlet manifold configured to receive a first fluid, a core in fluid communication with the inlet manifold, and an outlet manifold in fluid communication with the core. The inlet manifold includes a primary fluid channel and a plurality of secondary fluid channels. The primary fluid channel includes a fluid inlet and a first branched region distal to the fluid inlet. The plurality of secondary fluid channels are fluidly connected to the primary fluid channel at the first branched region. Each of the plurality of secondary fluid channels includes a first end and a second end opposite the first end. Each of the plurality of secondary fluid channels extends radially from the first branched region at the first end and has an equal length from a center of the first branched region to the second end. The outlet manifold similarly includes a primary fluid channel and a plurality of secondary fluid channels. The primary fluid channel includes a fluid inlet and a first branched region distal to the fluid inlet. The plurality of secondary fluid channels are fluidly connected to the primary fluid channel at the first branched region. Each of the plurality of secondary fluid channels includes a first end and a second end opposite the first end. Each of the plurality of secondary fluid channels extends radially from the first branched region at the first end and has an equal length from a center of the first branched region to the second end.

In another example, a method includes forming a core for a heat exchanger and additively manufacturing a first manifold for the heat exchanger. Additively manufacturing the first manifold includes additively building a branching tubular network. The network includes a primary fluid channel connected to a first branched region, a plurality of secondary fluid channels fluidly connected to the primary fluid channel at the first branched region, a second branched region, and a plurality of tertiary fluid channels fluidly connected to each of the plurality of secondary channels at the second branched region. Each of the plurality of secondary fluid channels includes a first end and a second end opposite the first end, wherein each of the plurality of secondary fluid channels extends radially from the first branched region at the first end and has an equal length from a center of the first branched region to the second end. The second branched region is adjacent to the second end of each of the plurality of secondary fluid channels. The primary fluid channel is symmetric about a first axis, the plurality of secondary fluid channels are symmetric about a second axis, and the second axis forms a non-zero angle with the first axis, such that each of the plurality of secondary fluid channels forms a build angle of 45 degrees or greater with a horizontal plane.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of a heat exchanger showing a manifold with radially converging geometry.

FIG. 2 is a perspective side view of an embodiment of the heat exchanger of FIG. 1 showing a manifold with radially converging and fractal geometry and secondary fluid channels with a shifted centerline.

FIG. 3 is a perspective side view of a heat exchanger including an inlet manifold and an outlet manifold.

DETAILED DESCRIPTION

A heat exchanger with a radially converging manifold is disclosed herein. The heat exchanger includes branched tubular inlet and outlet manifolds with fractal branching patterns and radially converging geometry. The heat exchanger manifolds can be additively manufactured at an optimal build angle to reduce internal structural support requirements.

For purposes of clarity and ease of discussion, FIGS. 1 and 2 will be described together. FIG. 1 is a schematic view of heat exchanger 10 showing manifold 12 with radially converging geometry. FIG. 2 shows a perspective side view of an embodiment of heat exchanger 10 with radially converging geometry and with shifted centerline S. Heat exchanger 10 includes manifold 12 fluidly connected to core 14. Manifold 12 includes first end 15, second end 16, fluid port 17, primary fluid channel 18, first branched region 20, secondary fluid channels 22, second branched regions 24, and tertiary fluid channels 26A-26N (“N” is used herein as an arbitrary integer). Heat exchanger 10 receives first fluid F₁ along first axis A₁ and interacts thermally with second fluid F₂ along second axis A₂. Center B of first branched region 20 illustrates a point at the center of a representative three-dimensional spherical space corresponding to first branched region 20 and second branched regions 24. The representative spherical space can be defined by radius r₁ and is represented by a dashed circle in FIG. 1. However, it should be understood that the actual three-dimensional shape of first branched region 20 and secondary fluid channels 22 need not be spherical.

Fluid port 17 forms an opening into the fluid system of heat exchanger 10. In the examples of FIGS. 1 and 2, fluid port 17 is configured as an opening into primary fluid channel 18 on first end 15 of manifold 12. Primary fluid channel 18 forms a first section of manifold 12. Primary fluid channel 18 extends along first axis A₁ between fluid port 17 and downstream first branched region 20. First branched region 20 forms an end of primary fluid channel 18 distal to fluid port 17. Secondary fluid channels 22 are fluidly connected to primary fluid channel 18 at first branched region 20. Though the examples of FIGS. 1 and 2 show first branched region 20 branching into four secondary fluid channels 22, it should be understood that in other examples, alternate configurations are possible, including more or fewer secondary fluid channels 22 extending from first branched region 20. Furthermore, though manifold 12 is represented in FIG. 2 as a substantially planar structure, secondary fluid channels 22 can also extend along additional parallel planes to form a layered structure.

Each secondary fluid channel 22 extends between first branched region 20 and downstream second branched region 24. Each secondary fluid channel 22 can form a relatively straight path between first branched region 20 and second branched regions 24. Secondary fluid channels 22 are radially converging such that a central longitudinal axis can be drawn through each of secondary fluid channels 22 to converge at center B. Additionally, secondary fluid channels 22 have radially equivalent lengths such that the length of each secondary fluid channel 22, as measured from center B to second branched region 24, is equal to radius r₁. Thus, a cross-sectional circumference of the representative sphere with center B and radius r₁ (e.g., as represented by dashed circle in FIG. 1) includes points corresponding to each of second branched regions 24. In the exaggerated schematic example of FIG. 1, each secondary fluid channel 22 is shown spaced along a representative circular arc corresponding to radius r₁. It should be understood that the circumferential distance along an arc (i.e., length of the circular arc) between each secondary fluid channel 22 can be very small (e.g., one hundredth of a millimeter, one tenth of a millimeter, a millimeter, a centimeter, or other distances), such that each secondary fluid channel is directed substantially along first axis A₁.

At second branched regions 24, each secondary fluid channel 22 is fluidly connected to downstream tertiary fluid channels 26A-26N. Though the example of FIG. 1 shows each of second branched regions 24 branching into two of tertiary fluid channels 26A-26N, it should be understood that in other examples, alternate configurations are possible, including more or fewer tertiary fluid channels 26A-26N extending from second branched regions 24 (e.g., as shown in FIG. 2). In some examples, heat exchanger 10 can have a fractal geometry defining the branching relationship between secondary fluid channels 22 and tertiary fluid channels 26A-26N, such that the number of tertiary fluid channels 26A-26N at each second branched region 24 is equal to the total number of secondary fluid channels 22. In yet other examples, the number of tertiary fluid channels 26A-26N extending from different second branched regions 24 can be varied throughout manifold 12.

The configuration and fractal geometry of secondary fluid channels 22 and tertiary fluid channels 26A-26N is shown in greater detail in FIG. 2. Secondary fluid channels 22 extend from primary fluid channel 18 at first branched region 20. The arrangement of secondary fluid channels 22 can be symmetric about centerline S. Thus, centerline S can separate the plurality of secondary fluid channels 22 into an equal number of secondary fluid channels 22 on each side of centerline S. Centerline S is shifted with respect to first axis A₁, such that it can form non-zero first angle δ with first axis A₁. That is, manifold 12 can be asymmetrical about first axis A₁ in the region of secondary fluid channels 22 (though manifold 12 can be symmetrical about first axis A₁ in the region of primary fluid channel 18). Due to the non-zero angle δ of centerline S with first axis A₁, each of secondary fluid channels 22 can form an angle of 45 degrees or greater with representative horizontal plane P. As shown in the example of FIG. 2, one of secondary fluid channels 22 forms angle θ with horizontal plane P. Angle θ can be, for example, 45 degrees.

Though the example of FIG. 2 shows each of second branched regions 24 branching into five tertiary fluid channels 26A-26N, it should be understood that in other examples, alternate configurations are possible, including more or fewer tertiary fluid channels 26A-26N extending from second branched regions 24. For example, the number of tertiary fluid channels 26A-26N at each second branched region 24 can be equal to the total number of secondary fluid channels 22. In yet other examples, the number of tertiary fluid channels 26A-26N extending from different second branched regions 24 can be varied throughout manifold 12.

Tertiary fluid channels 26A-26N extend from second branched region 24 to interface C with core 14 at second end 16 of manifold 12. Each tertiary fluid channel 26A-26N can form a relatively straight path between second branched regions 24 and interface C. Interface C passes through a center (not indicated in FIG. 2) of each tertiary fluid channel 26A-26N. In the example shown in FIG. 2, interface C is angled such that it is not perpendicular to first axis A₁, and each of tertiary fluid channels 26A-26N extends a different length between second branched region 24 and core 14. In other examples, each of tertiary fluid channels 26A-26N can extend an equal length between second branched region 24 and core 14.

First point D of interface C can correspond to a first one of tertiary fluid channels 26A-26N (e.g., tertiary fluid channel 26A in FIG. 2). End point E of interface C can correspond to a final one of tertiary fluid channels 26A-26N (e.g., tertiary fluid channel 26N in FIG. 2). In the example of FIG. 2, tertiary fluid channels 26A-26N are generally configured in ascending order by length from first point D to end point E laterally along the interface with core 14. However, because the length of each tertiary fluid channel 26A-26N is dependent, in part, on the radial position of the corresponding second branched region 24 and the geometry of core 14, it should be understood that alternate embodiments of heat exchanger 10 can include alternate configurations of tertiary fluid channels 26A-26N such that tertiary fluid channels 26A-26N are not arranged in ascending/descending order, but are instead configured to extend any length between second branched regions 24 and core 14. For example, in alternate embodiments, interface C can form a curved line or an irregular interface with core 14 that is not defined by a line.

Second end 16 of manifold 12 forms an interface between manifold 12 and core 14. In the examples of FIGS. 1 and 2, core 14 is shown with a rectangular geometry, such as a plate-fin heat exchanger, but it should be understood that alternative embodiments can include other core types and/or geometries. Within manifold 12, each of primary fluid channel 18, secondary fluid channels 22, and tertiary fluid channels 26A-26N can be tubular in structure to facilitate fluid flow. Further, manifold 12 can be additively manufactured to achieve varied tubular dimensions (e.g., cross-sectional area, wall thicknesses, curvature, etc.), and can be mated with traditional core sections (e.g., plate-fin) or with more complex, additively manufactured core sections. Though the example of FIG. 2 illustrates heat exchanger 10 as including a single manifold 12 with second end 16, it should be understood that in other examples, heat exchanger 10 can include more than one manifold structure interfacing with core 14. Multiple manifold structures can be arranged in a substantially similar manner to manifold 12 to form multiple interface regions with core 14 that are each substantially similar to second end 16.

With continued reference to FIGS. 1 and 2, heat exchanger 10 is configured to permit the transfer of heat between first fluid F₁ and second fluid F₂. For example, a transfer of heat can be associated with the use of first fluid F₁ and/or second fluid F₂ for cooling and/or lubrication of components in a larger system, such as a gas turbine engine or aerospace system. First fluid F₁ and second fluid F₂ can be any type of fluid, including air, water, lubricant, fuel, or another fluid. Heat exchanger 10 is described herein as providing heat transfer from first fluid F₁ to second fluid F₂; therefore, first fluid F₁ is at a greater temperature than second fluid F₂ at the point where first fluid F₁ enters heat exchanger 10 (i.e., first fluid F₁ is a “hot” fluid and second fluid F₂ is a “cold” fluid). However, other configurations of heat exchanger 10 can include second fluid F₂ at a greater temperature than first fluid F₁ (and, thus, second fluid F₂ would be the “hot” fluid and first fluid F₁ would be the “cold” fluid).

In the example of FIG. 1, first fluid F₁ is shown flowing generally along first axis A₁ to enter heat exchanger 10 at fluid port 17. In another example, the direction of flow of first fluid F₁ can be reversed such that first fluid F₁ exits heat exchanger 10 at fluid port 17. Furthermore, heat exchanger 10 can be arranged to receive second fluid F₂ at core 14 along second axis A₂ perpendicular to axis A₁ (i.e., a cross-flow arrangement as shown in FIG. 1), or to receive second fluid F₂ along an axis parallel to axis A₁ (not shown in FIG. 1) in an opposite flow direction (i.e., a counter-flow arrangement).

Fluid port 17 of manifold 12 is configured to receive or discharge first fluid F₁ flowing along first axis A₁. First fluid F₁ entering manifold 12 at fluid port 17 is channeled through primary fluid channel 18 to first branched region 20. At first branched region 20, first fluid F₁ flows into secondary fluid channels 22. First branched region 20 and secondary fluid channels 22 are configured in a radially converging manner (as described above) such that first fluid F₁ has an equivalent fluid flow path (i.e., there is no “path of least resistance”) through each of the plurality of secondary fluid channels 22. From first branched region 20, first fluid F₁ flows within secondary fluid channels 22 to reach second branched regions 24. At each second branched region 24, first fluid F₁ is channeled out from secondary fluid channel 22 into tertiary fluid channels 26A-26N. In the examples of FIGS. 1 and 2, first fluid F₁ flows directly from tertiary fluid channels 26A-26N into core 14. In alternative embodiments, manifold 12 can be configured to include additional levels of branching and intervening fluid channels fluidly connected downstream of tertiary fluid channels 26A-26N and upstream of core 14. Heat transfer between first fluid F₁ and second fluid F₂ can occur largely at core 14 of heat exchanger 10.

Manifold 12 and/or core 14 of heat exchanger 10 can be formed partially or entirely by additive manufacturing. For metal components (e.g., Inconel, aluminum, titanium, etc.) exemplary additive manufacturing processes include powder bed fusion techniques such as direct metal laser sintering (DMLS), laser net shape manufacturing (LNSM), electron beam manufacturing (EBM), to name a few, non-limiting examples. For polymer or plastic components, stereolithography (SLA) can be used. Additive manufacturing is particularly useful in obtaining unique geometries and for reducing the need for welds or other attachments (e.g., between a header and core). However, it should be understood that other suitable manufacturing processes can be used.

During an additive manufacturing process, heat exchanger 10, or manifold 12, or core 14 can be formed layer by layer. Each additively manufactured layer creates a new horizontal build plane to which a subsequent layer of heat exchanger 10 is fused. That is, the build plane for the additive manufacturing process remains horizontal but shifts vertically by defined increments (e.g., one micrometer, one hundredth of a millimeter, one tenth of a millimeter, a millimeter, or other distances) as manufacturing proceeds. The example of FIG. 2 shows heat exchanger 10 already fully manufactured. Thus, horizontal plane P in FIG. 2 is a representative horizontal plane corresponding to a previous build plane as heat exchanger 10 was manufactured. From the portion of heat exchanger 10 manufactured up to horizontal plane P, the example of FIG. 2 shows one of secondary fluid channels 22 was further manufactured at angle θ to horizontal plane P.

In general, the radially converging profile of manifold 12 retains the benefits of fractal geometry compared to traditional heat exchanger header configurations. Traditional heat exchanger headers, such as those with box-shaped manifolds, can have increased stress concentration at the interface between the manifold and the core, particularly at corners of the manifold where there is geometry discontinuity. The branching pattern of fractal heat exchanger manifolds, wherein each fluid channel is individually and directly connected to a passage in the core as shown in FIGS. 1 and 2, can reduce this geometry discontinuity. Furthermore, each fluid channel in a fractal heat exchanger manifold (e.g., manifold 12) behaves like a slim beam with low stiffness in transverse directions and reduced stiffness in horizontal directions due to the curved shape at each branched region. Thus, fractal heat exchanger manifolds have increased compliance (i.e., reduced stiffness) and experience less thermal stress compared to traditional heat exchanger header configurations.

Some complex heat exchangers or parts can require additional internal or external support structures during additive manufacturing to ensure structural integrity of the part. Internal support structures are not typically removed from a heat exchanger manifold after manufacture. Presence of internal support structures can cause increased resistance (i.e., pressure drop) within the manifold and, thereby, inefficient transfer of heat between first fluid F₁ and second fluid F₂, so it is beneficial to reduce the internal support requirements of a build. One option for reducing internal support requirements is to align the fluid channels of the heat exchanger manifold with respect to the particular build orientation. However, aligning these channels in typical fractal geometry configurations can create a path of least resistance for the fluid flowing through the heat exchanger, such that the fluid is biased to flow through the shortest path within the heat exchanger. A path of least resistance can cause a pressure drop in the fluid flow, and, thereby, decrease the efficiency of the heat exchanger.

The radially converging profile of manifold 12 provides for improved fluid flow through heat exchanger 10. Because each radially converging secondary fluid channel 22 has an equal length between center B of first branched region 20 and each second branched region 24, there is no path of least resistance for first fluid F₁ to take through heat exchanger 10. Thus, manifold 12 can reduce the pressure drop caused by aligning manifold 12 with respect to a build orientation.

Furthermore, the radially converging profile of manifold 12 and the shifted centerline S of secondary fluid channels 22, as described above with reference to FIG. 2, enable manifold 12 to be additively manufactured at an optimal build angle. For example, an optimal build angle for additive manufacturing of a heat exchanger manifold can be 45 degrees or greater to a horizontal build plane (e.g., horizontal plane P in FIG. 2). When a radially converging profile is utilized, but the centerline of the secondary fluid channels is not shifted (i.e., if secondary fluid channels 22 are symmetric about first axis A₁ within manifold 12), some of the walls of secondary fluid channels 22 can be oriented at less than 45 degrees to the build platform. At angles below the optimal build angle, there can be an increased requirement for internal structural support during an additive manufacturing build to maintain structural integrity of the manifold. However, when centerline S is shifted as described herein, all walls of all secondary fluid channels 22 in radially converging manifold 12 can be oriented at 45 degrees or greater to a horizontal build plane or build platform. The build orientation enabled by radially converging manifold 12 can, thereby, have decreased internal support requirements, and the resulting manifold can have improved efficiency.

An embodiment of heat exchanger 110 with inlet manifold 112_i and outlet manifold 112_o is shown in perspective side view in FIG. 3. Heat exchanger 110 is substantially similar to heat exchanger 10, and additionally includes core 114 disposed between fluidly connected inlet manifold 112_i and outlet manifold 112_o. Inlet manifold 112_i includes first end 115_i, second end 116_i, and fluid inlet 117_i. Outlet manifold 112_o similarly includes first end 115_o, second end 116_o, and fluid outlet 117_o.

In serial fluid communication with each of fluid inlet 117_i and fluid outlet 117_o (denoted in FIG. 3 with the applicable “i” or “o” subscript, but generally referred to herein solely by reference number) are primary fluid channel 118, first branched region 120, secondary fluid channels 122, second branched regions 124, and tertiary fluid channels 126A-126N. Tertiary fluid channels 126A-126N form interface C between each of inlet manifold 112_i and outlet manifold 112_o and core 114 at second end 116. Each of inlet manifold 112_i and outlet manifold 112_o can include secondary fluid channels 122 with radially converging geometry and shifted centerline S, as described above with reference to FIGS. 1 and 2. Centerline S_i of inlet manifold 112_i and centerline S_o of outlet manifold 112 can be parallel, such that each of secondary fluid channels 122_i corresponds to one of secondary fluid channels 122_o that forms a same angle with a horizontal plane (not shown in FIG. 3). Similarly, as shown in the example of FIG. 3, primary fluid channel 118_o of outlet manifold 112_o can be centered about outlet axis A₃, which can be parallel to first axis A₁. In other examples, primary fluid channel 118_o of outlet manifold 112_o can also be centered about first axis A₁, such that primary fluid channel 118_o of outlet manifold 112_o and primary fluid channel 118_i of inlet manifold 112_i are directly aligned.

In the example of FIG. 3, interface C_i of inlet manifold 112_i and interface C_o of outlet manifold 112_o are parallel along opposite ends of core 114 corresponding to second end 116_i and second end 116_o, respectively. It should be understood that because interface C_i and interface C_o depend on the geometry of tertiary fluid channels 126A-126N (as described above with reference to tertiary fluid channels 26A-26N in FIG. 2), inlet manifold 112_i and outlet manifold 112_o can be configured in alternate embodiments such that interface C_i and interface C_o are not parallel. Furthermore, though the example of FIG. 3 shows outlet manifold 112_o mirrors and is slightly offset from inlet manifold 112_i on an opposite side of core 114, it should be understood that in other examples, depending on the geometry of core 114, outlet manifold 112_o can be aligned with inlet manifold 112_i. In yet other examples, outlet manifold 112_o can have a different configuration than inlet manifold 112_i, such as different levels of branching, different numbers of branches at each branched region, or a different overall geometry.

In a manner that is substantially similar to that described above with reference to FIGS. 1 and 2, heat exchanger 110 is configured to permit the transfer of heat between first fluid F₁ and second fluid F₂ (FIG. 1). In the example of FIG. 3, first fluid F₁ is shown flowing generally along first axis A₁ to enter heat exchanger 110 at fluid inlet 117_i. First fluid F₁ passes through the branching tubular network (primary fluid channel 118_i, first branched region 120_i, secondary fluid channels 122_i, second branched regions 124_i, and tertiary fluid channels 126A_i-126N_i) of inlet manifold 112_i, through core 114, to the branching tubular network (tertiary fluid channels 126A_o-126N_o, second branched regions 124_o, secondary fluid channels 122_o, first branched region 120_o, and primary fluid channel 118_o) of outlet manifold 112_o, and exits heat exchanger 110 at fluid outlet 117_o. Heat exchanger 110 is configured such that first fluid F₁ encounters the same branching tubular network within outlet manifold 112_o as in inlet manifold 112_i in reverse order. In another example, the direction of flow of first fluid F₁ can be reversed such that first fluid F₁ enters heat exchanger 110 at fluid outlet 117_o and exits at fluid inlet 117_i. Furthermore, heat exchanger 110 can be arranged to receive second fluid F₂ (FIG. 1) at core 14 along second axis A₂ (FIG. 1) perpendicular to axis A₁ (i.e., a cross-flow arrangement as shown in FIG. 1), or to receive second fluid F₂ along an axis parallel to axis A₁ (not shown in FIG. 1) in an opposite flow direction (i.e., a counter-flow arrangement).

Thus, heat exchanger 110 is configured to facilitate the transfer of heat between first fluid F₁ and second fluid F₂ (FIG. 1) at core 114. First fluid F₁, exiting heat exchanger 110 at fluid outlet 117_o, can have a final temperature (e.g., after heat transfer has occurred and equilibrium is reached) that is suitable for cooling and/or lubrication of components in a larger system, such as a gas turbine engine or aerospace system.

Heat exchanger 110 presents the same benefits as described above in relation to heat exchanger 10, including equivalent paths for fluid flow such that there is no path of least resistance and no resulting pressure drop and geometry that enables heat exchanger 110 to be additively manufactured with reduced internal structural support. As shown in FIG. 3, centerline S of secondary fluid channels 122 of both inlet manifold 112_i and outlet manifold 112_o can be shifted such that all walls of secondary fluid channels 122 of heat exchanger 110 can have an optimal build angle of 45 degrees or greater (not shown in FIG. 3) to a horizontal build plane for additive manufacturing. Accordingly, the techniques of this disclosure enable heat exchanger 110 to provide more effective heat transfer by reducing internal structural support requirements.

Discussion of Possible Embodiments

The following are non-exclusive descriptions of possible embodiments of the present invention.

A heat exchanger manifold configured to receive or discharge a first fluid includes a primary fluid channel and a plurality of secondary fluid channels. The primary fluid channel includes a fluid port and a first branched region distal to the fluid port. The plurality of secondary fluid channels are fluidly connected to the primary fluid channel at the first branched region. Each of the plurality of secondary fluid channels includes a first end and a second end opposite the first end. Each of the plurality of secondary fluid channels extends radially from the first branched region at the first end and has an equal length from a center of the first branched region to the second end.

The heat exchanger 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:

Each of the plurality of secondary fluid channels can provide an equivalent path for directing fluid flow of the first fluid.

Each of the plurality of secondary fluid channels can be tubular.

The primary fluid channel can be symmetric about a first axis, the plurality of secondary fluid channels can be symmetric about a second axis, and the second axis can form a non-zero angle with the first axis.

The heat exchanger manifold can further include a second branched region adjacent to the second end of each of the plurality of secondary fluid channels, and a plurality of tertiary fluid channels fluidly connected to each of the plurality of secondary channels at the second branched region.

The heat exchanger manifold can have a fractal geometry.

Each of the plurality of secondary fluid channels can be tubular, and each of the plurality of tertiary fluid channels can be tubular.

The heat exchanger manifold can further include a heat exchanger core, wherein the plurality of tertiary fluid channels can be fluidly connected to the heat exchanger core.

The heat exchanger manifold can be additively manufactured at a build angle of 45 degrees or greater to a horizontal plane based on structural support requirements for additive manufacturing.

A heat exchanger includes and inlet manifold configured to receive a first fluid, a core in fluid communication with the inlet manifold, and an outlet manifold in fluid communication with the core. The inlet manifold includes a primary fluid channel and a plurality of secondary fluid channels. The primary fluid channel includes a fluid inlet and a first branched region distal to the fluid inlet. The plurality of secondary fluid channels are fluidly connected to the primary fluid channel at the first branched region. Each of the plurality of secondary fluid channels includes a first end and a second end opposite the first end. Each of the plurality of secondary fluid channels extends radially from the first branched region at the first end and has an equal length from a center of the first branched region to the second end. The outlet manifold similarly includes a primary fluid channel and a plurality of secondary fluid channels. The primary fluid channel includes a fluid inlet and a first branched region distal to the fluid inlet. The plurality of secondary fluid channels are fluidly connected to the primary fluid channel at the first branched region. Each of the plurality of secondary fluid channels includes a first end and a second end opposite the first end. Each of the plurality of secondary fluid channels extends radially from the first branched region at the first end and has an equal length from a center of the first branched region to the second end.

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:

Each of the plurality of secondary fluid channels of the inlet manifold and of the outlet manifold can provide an equivalent path for directing fluid flow of the first fluid.

Each of the plurality of secondary fluid channels of the inlet manifold and of the outlet manifold can be tubular.

The primary fluid channel of the inlet manifold and of the outlet manifold can be symmetric about a first axis, the plurality of secondary fluid channels of the inlet manifold and of the outlet manifold can be symmetric about a second axis, and the second axis can form a non-zero angle with the first axis.

The heat exchanger can further include a second branched region adjacent to the second end of each of the plurality of secondary fluid channels of the inlet manifold and of the outlet manifold, and a plurality of tertiary fluid channels fluidly connected to each of the plurality of secondary channels of the inlet manifold and of the outlet manifold at the second branched region.

At least one of the inlet manifold and the outlet manifold can have a fractal geometry.

Each of the plurality of secondary fluid channels of the inlet manifold and of the outlet manifold can be tubular, and each of the plurality of tertiary fluid channels of the inlet manifold and of the outlet manifold can be tubular.

The plurality of tertiary fluid channels of the inlet manifold and of the outlet manifold can be fluidly connected to the core.

The inlet manifold and the outlet manifold can be additively manufactured at a build angle of 45 degrees or greater to a horizontal plane based on structural support requirements for additive manufacturing.

A method includes forming a core for a heat exchanger and additively manufacturing a first manifold for the heat exchanger. Additively manufacturing the first manifold includes additively building a branching tubular network. The network includes a primary fluid channel connected to a first branched region, a plurality of secondary fluid channels fluidly connected to the primary fluid channel at the first branched region, a second branched region, and a plurality of tertiary fluid channels fluidly connected to each of the plurality of secondary channels at the second branched region. Each of the plurality of secondary fluid channels includes a first end and a second end opposite the first end, wherein each of the plurality of secondary fluid channels extends radially from the first branched region at the first end and has an equal length from a center of the first branched region to the second end. The second branched region is adjacent to the second end of each of the plurality of secondary fluid channels. The primary fluid channel is symmetric about a first axis, the plurality of secondary fluid channels are symmetric about a second axis, and the second axis forms a non-zero angle with the first axis, such that each of the plurality of secondary fluid channels forms a build angle of 45 degrees or greater with a horizontal plane.

The method of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations, operations, and/or additional components:

The build angle can be based on structural support requirements for additive manufacturing.

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.

Claims

1. A heat exchanger manifold configured to receive or discharge a first fluid, the manifold comprising: a primary fluid channel, the primary fluid channel comprising: a fluid port; anda first branched region distal to the fluid port; andsecondary fluid channels with radially equal lengths such that a flow path through each of the secondary fluid channels is equivalent, the secondary fluid channels fluidly connected to the primary fluid channel at the first branched region, each of the secondary fluid channels comprising: a first end connected to the primary fluid channel; anda second end opposite the first end;wherein the primary fluid channel is symmetric about a first axis and an arrangement of at least three secondary fluid channels that are spaced along an arc is symmetric about a second common axis that forms a non-zero angle with the first axis.

2. The heat exchanger manifold of claim 1, further comprising: Tertiary fluid channels fluidly connected to each of the secondary fluid channels at a respective second branched region that is adjacent to the second end of a respective one of the secondary fluid channels to form a consecutively branching structure of the heat exchanger manifold; andwherein each of the secondary fluid channels extends radially from the first branched region such that a respective longitudinal axis of each of the secondary fluid channels converges at a point.

3. The heat exchanger manifold of claim 1, wherein each of the secondary fluid channels extends radially from the first branched region such that a respective longitudinal axis of each of the secondary fluid channels converges at a point.

4. The heat exchanger manifold of claim 1, further comprising: tertiary fluid channels fluidly connected to each of the secondary fluid channels at a respective second branched region that is adjacent to the second end of a respective one of the secondary fluid channels.

5. The heat exchanger manifold of claim 4, wherein the heat exchanger manifold has a fractal geometry.

6. The heat exchanger manifold of claim 4, wherein each of the secondary fluid channels is tubular, and wherein each of the tertiary fluid channels is tubular.

7. The heat exchanger manifold of claim 4, wherein the tertiary fluid channels are configured to be fluidly connected to a heat exchanger core.

8. The heat exchanger manifold of claim 7, wherein the heat exchanger manifold is configured to be additively manufactured at a build angle of 45 degrees or greater to a horizontal plane based on structural support requirements for additive manufacturing.

9. A heat exchanger comprising: an inlet manifold configured to receive a first fluid, the inlet manifold comprising: a primary fluid channel, the primary fluid channel comprising: a fluid inlet; anda first branched region distal to the fluid inlet; andsecondary fluid channels with radially equal lengths such that a flow path through each of the secondary fluid channels is equivalent, the secondary fluid channels fluidly connected to the primary fluid channel at the first branched region, each of the secondary fluid channels comprising: a first end connected to the primary fluid channel; anda second end opposite the first end;a core in fluid communication with the inlet manifold; andan outlet manifold in fluid communication with the core, the outlet manifold comprising: a primary fluid channel, the primary fluid channel comprising: a fluid outlet; anda first branched region distal to the fluid outlet; andsecondary fluid channels with radially equal lengths such that a flow path through each of the secondary fluid channels is equivalent, the secondary fluid channels fluidly connected to the primary fluid channel at the first branched region, each of the secondary fluid channels comprising: a first end connected to the primary fluid channel; anda second end opposite the first end;wherein the primary fluid channel of the inlet manifold and of the outlet manifold are each symmetric about a respective first axis and arrangements of at least three secondary fluid channels of the inlet manifold and of the outlet manifold that are spaced along respective arcs are each symmetric about a respective second common axis that forms a non-zero angle with the corresponding first axis.

10. The heat exchanger of claim 9, further comprising: tertiary fluid channels fluidly connected to each of the secondary fluid channels of the inlet manifold and the outlet manifold at a respective second branched region that is adjacent to the second end of a respective one of the secondary fluid channels to form consecutively branching structures of the inlet manifold and the outlet manifold;wherein each of the secondary fluid channels of the inlet manifold extends radially from the first branched region of the inlet manifold such that a respective longitudinal axis of each of the secondary fluid channels of the inlet manifold converges at a first point; andwherein each of the secondary fluid channels of the outlet manifold extends radially from the first branched region of the outlet manifold such that a respective longitudinal axis of each of the secondary fluid channels of the outlet manifold converges at a second point.

11. The heat exchanger of claim 9, wherein each of the secondary fluid channels of the inlet manifold extends radially from the first branched region of the inlet manifold such that a respective longitudinal axis of each of the secondary fluid channels of the inlet manifold converges at a first point; and wherein each of the secondary fluid channels of the outlet manifold extends radially from the first branched region of the outlet manifold such that a respective longitudinal axis of each of the secondary fluid channels of the outlet manifold converges at a second point.

12. The heat exchanger of claim 9, further comprising: tertiary fluid channels fluidly connected to each of the secondary fluid channels of the inlet manifold and the outlet manifold at a respective second branched region that is adjacent to the second end of a respective one of the secondary fluid channels.

13. The heat exchanger of claim 12, wherein at least one of the inlet manifold and the outlet manifold has a fractal geometry.

14. The heat exchanger of claim 12, wherein each of the secondary fluid channels of the inlet manifold and the outlet manifold is tubular, and wherein each of the tertiary fluid channels of the inlet manifold and of the outlet manifold is tubular.

15. The heat exchanger of claim 12, wherein the tertiary fluid channels of the inlet manifold and the outlet manifold are fluidly connected to the core.

16. The heat exchanger of claim 15, wherein the inlet manifold and the outlet manifold are configured to be additively manufactured at a build angle of 45 degrees or greater to a horizontal plane based on structural support requirements for additive manufacturing.

17. A method of additively manufacturing a heat exchanger, the method comprising: forming a core of the heat exchanger;additively building a branching tubular network of a first manifold of the heat exchanger, the branching tubular network comprising: a primary fluid channel connected to a first branched region;secondary fluid channels with radially equal lengths such that a flow path through each of the secondary fluid channels is equivalent, the secondary fluid channels fluidly connected to the primary fluid channel at the first branched region, each of the secondary fluid channels comprising: a first end connected to the primary fluid channel; anda second end opposite the first end; andtertiary fluid channels fluidly connected to each of the secondary channels at a respective second branched region that is adjacent to the second end of a respective one of the secondary fluid channels;wherein the primary fluid channel is symmetric about a first axis, an arrangement of at least three secondary fluid channels that are spaced along an arc is symmetric about a second common axis, and the second common axis forms a non-zero angle with the first axis.

18. The method of claim 17, wherein each of the secondary fluid channels extends radially from the first branched region such that a respective longitudinal axis of each of the secondary fluid channels converges at a point.

19. The method of claim 17, further comprising: orienting the branching tubular network such that each of the secondary fluid channels is manufactured at a build angle of 45 degrees or greater with a horizontal plane.

20. The method of claim 19, wherein the build angle is based on structural support requirements for additive manufacturing.