Weaved cross-flow heat exchanger and method of forming a heat exchanger

Abstract

A heat exchanger is disclosed herein that includes three walls that are each shaped in a wave pattern with the waves that extend in both a first lateral direction and a second lateral direction. A second wall is adjacent to and in contact with a first wall with the waves of the second wall being offset from the waves of the first wall by one-half wavelength in the first direction. The third wall is adjacent to and in contact with the second wall with the waves of the third wall being offset from the waves to the second wall by one-half wavelength in the second direction. The first wall and second wall form a first plurality of flow paths extending in the second direction, and the second wall and the third wall for a second plurality of flow paths extending in the first direction.

1 . A heat exchanger extending laterally in a first direction and a second direction, the heat exchanger comprising:
 a first wall shaped in a wave pattern with waves that extend in both the first direction and the second direction;   a second wall adjacent to and in contact with the first wall with the second wall being shaped in a wave pattern with waves that extend in both the first direction and the second direction, the waves of the second wall being offset in the first direction from the waves of the first wall by one-half wavelength;   a third wall adjacent to and in contact with the second wall with the third wall being shaped in a wave pattern with waves that extend in both the first direction and the second direction, the waves of the third wall being offset in the second direction from the second wall by one-half wavelength;   a first plurality of flow paths extending in the second direction with the first plurality of flow paths each bounded by the first wall and the second wall; and   a second plurality of flow paths extending in the first direction with the second plurality of flow paths each bounded by the second wall and the third wall.   
     
     
         2 . The heat exchanger of  claim 1 , further comprising:
 a fourth wall adjacent to and in contact with the third wall with the fourth wall being shaped in a wave pattern with waves that extend in both the first direction and the second direction, the waves of the fourth wall being offset from the waves of the third wall in the first direction by one-half wavelength; and   a third plurality of flow paths extending in the second direction with the third plurality of flow paths each bounded by the third wall and the fourth wall.   
     
     
         3 . The heat exchanger of  claim 1 , wherein the waves of the first wall are based on a sinusoidal curve in the first direction and a sinusoidal curve in the second direction, and wherein the waves of the second wall are based on a sinusoidal curve in the first direction and a sinusoidal curve in the second direction. 
     
     
         4 . The heat exchanger of  claim 1 , wherein each flow path of the first plurality of flow paths and the second plurality of flow paths have a substantially circular cross-sectional area. 
     
     
         5 . The heat exchanger of  claim 4 , wherein the first plurality of flow paths are laterally interconnected by first transition openings and the second plurality of flow paths are laterally interconnected by second transition openings such that flow through one flow path of the first plurality of flow paths can transition and flow through an adjacent flow path of the first plurality of flow paths and flow through one flow path of the second plurality of flow paths can transition and flow through an adjacent flow path of the second plurality of flow paths. 
     
     
         6 . The heat exchanger of  claim 1 , wherein each flow path of the first plurality of flow paths are fluidically isolated from one another and each flow path of the second plurality of flow paths are fluidically isolated from one another. 
     
     
         7 . The heat exchanger of  claim 6 , wherein the first wall contacts and connects to the second wall along a plurality of contact lines extending in the second direction to form the fluidically isolated first plurality of flow paths extending in the second direction. 
     
     
         8 . The heat exchanger of  claim 6 , wherein the second wall contacts and connects to the third wall along a plurality of contact lines extending in the first direction to form the fluidically isolated second plurality of flow paths extending in the first direction. 
     
     
         9 . The heat exchanger of  claim 1 , wherein the first wall, second wall, and third wall are constructed by additive manufacturing so that the heat exchanger is one continuous and monolithic component. 
     
     
         10 . The heat exchanger of  claim 1 , wherein the waves in the first direction of the first wall, the waves in the first direction of the second wall, and the waves in the first direction of the third wall have an amplitude that is greater than an amplitude of the waves in the second direction of the first wall, the waves in the second direction of the second wall, and the waves in the second direction of the third wall. 
     
     
         11 . The heat exchanger of  claim 10 , wherein the amplitude of the waves in the first direction of the first wall, second wall, and third wall is at least 1.5 times greater than the amplitude of the waves in the second direction of the first wall, second wall, and third wall. 
     
     
         12 . The heat exchanger of  claim 10 , wherein the waves in the first direction of the first wall, the waves in the first direction of the second wall, and the waves in the first direction of the third wall have a wavelength that is greater than a wavelength of the waves in the second direction of the first wall, the waves in the second direction of the second wall, and the waves in the second direction of the third wall. 
     
     
         13 . The heat exchanger of  claim 1 , wherein the first wall, second wall, and third wall are constructed from a material having low thermal conductivity. 
     
     
         14 . A gas turbine engine comprising the heat exchanger of  claim 1 . 
     
     
         15 . The gas turbine engine of  claim 14 , wherein a first fluid flows through the first plurality of flow paths and a second fluid flows through the second plurality of flow paths. 
     
     
         16 . A method of forming a heat exchanger, the method comprising:
 forming a first wall with waves that extend laterally in both a first direction and in a second direction;   forming a second wall adjacent to and in contact with the first wall with waves that extend laterally in both the first direction and in the second direction, the waves of the second wall being offset in the first direction from the waves of the first wall by one-half wavelength;   forming a third wall adjacent to and in contact with the second wall with waves that extend laterally in both the first direction and in the second direction, the waves of the third wall being offset in the second direction from the waves of the second wall by one-half wavelength,   wherein the first wall and the second wall bound a first plurality of flow paths that extend in the second direction, and wherein the second wall and the third wall bound a second plurality of flow paths that extend in the first direction.   
     
     
         17 . The method of  claim 16 , further comprising:
 additively manufacturing the first wall, second wall, and third wall.   
     
     
         18 . The method of  claim 16 , further comprising:
 forming a fourth wall adjacent to and in contact with the third wall with waves that extend laterally in both the first direction and in the second direction, the waves being offset in the first direction from the waves of the third wall by one-half wavelength,   wherein the third wall and fourth wall bound a third plurality of flow paths that extend in the second direction.   
     
     
         19 . The method of  claim 16 , wherein the waves of the first wall are based on a sinusoidal curve in the first direction and a sinusoidal curve in the second direction, and wherein the waves of the second wall are based on a sinusoidal curve in the first direction and a sinusoidal curve in the second direction. 
     
     
         20 . A method of transferring thermal energy through the use of a heat exchanger, the method comprising:
 flowing a first fluid through a first plurality of flow paths bounded by a first wall and a second wall, the first wall having a wave pattern with waves that are based on a sinusoidal curve and extend laterally in both a first direction and a second direction, the second wall being adjacent to and in contact with the first wall and having a wave pattern with waves that are based on a sinusoidal curve and extend laterally in both the first direction and the second direction, the waves of the second wall being offset in the first direction from the waves of the first wall by one-half wavelength;   flowing a second fluid through a second plurality of flow paths bounded by the second wall and a third wall, the third wall being adjacent to and in contact with the second wall, the third wall having a wave pattern with waves that are based on a sinusoidal curve and extend laterally in both the first direction and the second direction, the waves of the third wall being offset in the second direction from the waves of the second wall by one-half wavelength.