Heat exchanger low pressure loss manifold

Abstract

A heat exchanger includes a plurality of flow passages in thermal contact with a cooling flow. The plurality of flow passages include a first end and a second end. An inlet manifold is at the first end of the plurality of flow passages. The inlet manifold includes a plurality of independent splitter passages that communicate airflow to the first end of the plurality of flow passages. An exhaust manifold is at the second end of the plurality of flow passages. A method is also disclosed.

What is claimed is: 
     
         1 . A heat exchanger comprising:
 a plurality of flow passages in thermal contact with a cooling flow, the plurality of flow passages including a first end and a second end;   an inlet manifold at the first end of the plurality of flow passages, the inlet manifold including a plurality of independent splitter passages that communicate airflow to the first end of the plurality of flow passages; and   an exhaust manifold at the second end of the plurality of flow passages.   
     
     
         2 . The heat exchanger as recited in  claim 1 , wherein each of the plurality of splitter passages include a flow area between an inlet of the inlet manifold and an outlet of the inlet manifold into the first end of the plurality of passages that are the same. 
     
     
         3 . The heat exchanger as recited in  claim 2 , wherein a ratio between an area of the inlet and an area of the outlet of each of the plurality of splitter passages is between 1.5 and 5. 
     
     
         4 . The heat exchanger as recited in  claim 2 , wherein the inlet comprises a circular shape in cross-section and is divided into passage inlets of equal area that correspond with each of the plurality of splitter passages. 
     
     
         5 . The heat exchanger as recited in  claim 4 , wherein each of the passage inlets are pie-shaped in cross-section. 
     
     
         6 . The heat exchanger as recited in  claim 4 , wherein each of the passage inlets are circular shaped in cross-section. 
     
     
         7 . The heat exchanger as recited in  claim 4 , wherein the outlet comprises a rectangular shape in cross-section and is divided into passage outlets of equal area that correspond with the plurality of splitter passages. 
     
     
         8 . The heat exchanger as recited in  claim 7 , wherein each of the passage outlets is in communication with more than one of the plurality of flow passages. 
     
     
         9 . The heat exchanger as recited in  claim 2 , wherein each of the plurality of splitter passages comprises a smooth curved passage without interruption between the inlet and the outlet. 
     
     
         10 . The heat exchanger as recited in  claim 1 , wherein the exhaust manifold includes an inlet portion at the second end of the plurality of flow passages and an outlet portion, wherein the exhaust manifold includes a plurality of exhaust passages defining separate flow passages between the inlet portion and the outlet portion. 
     
     
         11 . The heat exchanger as recited in  claim 10 , wherein the inlet portion is divided into a plurality of rectangular inlets corresponding with the second end of the plurality of flow passages. 
     
     
         12 . The heat exchanger as recited in  claim 10 , wherein each of the outlet portions comprises a plurality of outlets having one of a pie-shaped cross-section and curvilinear shaped cross-section. 
     
     
         13 . A method of forming a manifold for a heat exchanger comprising:
 creating a plurality of core sections that define a passageway between an inlet and an outlet, wherein each of the plurality of core sections define a common inlet area and outlet area for the passageway;   defining a mold cavity to receive the core sections that defines an outer shape of the manifold;   molding the plurality of core sections within the mold cavity to encase the core sections within a casting material; and   removing the core sections from the casting material.   
     
     
         14 . The method as recited in  claim 13 , wherein each of the core sections defines an area ratio between the inlet and the outlet of between 1.5 and 5. 
     
     
         15 . The method as recited in  claim 13 , wherein the core sections define the inlet as one of a pie-shaped and a curvilinear shape in cross-section. 
     
     
         16 . The method as recited in  claim 15 , wherein each of the core sections define a smooth curved passage without interruption between the inlet and the outlet. 
     
     
         17 . The method as recited in  claim 13 , wherein the plurality of core sections together define a circular inlet in cross-section. 
     
     
         18 . The method as recited in  claim 13 , wherein the core defines a substantially rectangular outlet in cross-section.