Contoured wall heat exchanger

Abstract

A heat exchanger and heat exchanger core are provided. The heat exchanger core includes a plurality of columnar passages extending between an inlet plenum of the heat exchanger core and an outlet plenum of the heat exchanger core, the columnar passages formed monolithically in a single fabrication process.

What is claimed is: 
     
         1 . A heat exchanger core comprising a plurality of columnar passages extending between an inlet plenum of the heat exchanger core and an outlet plenum of the heat exchanger core, the columnar passages formed monolithically in a single fabrication process, each of the columnar passages being separated by core passage walls, each of the core passage walls having a cross-section with alternating concave and convex portions. 
     
     
         2 . The heat exchanger core of  claim 1 , wherein the core passage walls are separated by a flow gap. 
     
     
         3 . The heat exchanger core of  claim 2 , wherein at least one of the core passage walls includes a plurality of surface features that extend into the flow gap. 
     
     
         4 . The heat exchanger core of  claim 1 , wherein the plurality of columnar passages include: a first set of first passages coupled in parallel flow communication; and a second set of second passages coupled in parallel flow communication, the second set of second passages isolated from flow communication with the first set of first passages. 
     
     
         5 . The heat exchanger core of  claim 4 , further including a third set of third passages coupled in parallel flow communication, the third set of third passages isolated from flow communication with the first set of first passages and the second set of second passages. 
     
     
         6 . The heat exchanger core of  claim 4 , wherein at least one of the first set of first passages or the second set of second passages includes individual core flow passages that are sized differently than the remaining core flow passages of the at least one of the first set of first passages or the second set of second passages. 
     
     
         7 . The heat exchanger core of  claim 4 , wherein the first set of first passages and the second set of second passages are coupled in thermal conductive communication with each other along a length of the first set of first passages and the second set of second passages between the inlet plenum of the heat exchanger core and the outlet plenum of the heat exchanger core. 
     
     
         8 . The heat exchanger core of  claim 1 , wherein the plurality of columnar passages includes a plurality of flow guides. 
     
     
         9 . The heat exchanger core of  claim 1 , wherein the plurality of columnar passages includes at least one of a plurality of dimples, a plurality of bumps, or a plurality of spikes. 
     
     
         10 . The heat exchanger core of  claim 1 , further including a first heat exchanger manifold and a second heat exchanger manifold, a transition member formed on each end of at least one of the first heat exchanger manifold or the second heat exchanger manifold, the transition member including a plurality of guide vanes configured to direct a flow of fluid from the at least one of the first heat exchanger manifold and the second heat exchanger manifold to respective passages of the plurality of columnar passages of the heat exchanger core. 
     
     
         11 . A heat exchanger comprising a heat exchanger body, the heat exchanger body including:
 a first heat exchanger manifold;   a second heat exchanger manifold;   a serpentine heat exchanger core between the first heat exchanger manifold and the second heat exchanger manifold, the serpentine heat exchanger core having a plurality of working fluid passages extending along a serpentine path created by the serpentine heat exchanger core between the first heat exchanger manifold and the second heat exchanger manifold; and   a plurality of coolant fluid passages extending along the serpentine path in thermal conduction contact with the plurality of working fluid passages,   wherein the first heat exchanger manifold, the second heat exchanger manifold, the plurality of working fluid passages, and the plurality of coolant fluid passages are formed monolithically of a sintered material, and wherein each of the plurality of working fluid passages is separated by core passage walls, each of the core passage walls having a corrugated cross-section.   
     
     
         12 . The heat exchanger of  claim 11 , wherein the serpentine path includes at least one of a simple arcuate path, a complex arcuate path, a zig-zag path, an undulating path, a straight path, or a linear path. 
     
     
         13 . The heat exchanger of  claim 11 , wherein the first heat exchanger manifold includes a working fluid inlet header and a coolant fluid outlet header, and wherein the second heat exchanger manifold includes a working fluid outlet header and a coolant fluid inlet header. 
     
     
         14 . The heat exchanger of  claim 11 , wherein the first heat exchanger manifold includes a working fluid inlet header and a working fluid outlet header, and wherein the second heat exchanger manifold includes a coolant fluid outlet header and a coolant fluid inlet header. 
     
     
         15 . The heat exchanger of  claim 11 , further including a first header member formed monolithically with the heat exchanger body, the first header member including a first opening, a second opening, and a working fluid plenum extending therebetween, the first header member including a third opening, a fourth opening, and a coolant fluid plenum extending therebetween. 
     
     
         16 . The heat exchanger of  claim 11 , further including a second header member formed monolithically with the heat exchanger body, the second header member including a first opening, a second opening, and a working fluid plenum extending therebetween, the second header member including a third opening, a fourth opening, and a coolant fluid plenum extending therebetween. 
     
     
         17 . The heat exchanger of  claim 11 , wherein the first heat exchanger manifold, the second heat exchanger manifold, the plurality of working fluid passages, and the plurality of coolant fluid passages are formed together seallessly. 
     
     
         18 . The heat exchanger of  claim 11 , wherein at least one of the first heat exchanger manifold or the second heat exchanger manifold includes a flange monolithically formed with the at least one of the first heat exchanger manifold or the second heat exchanger manifold. 
     
     
         19 . The heat exchanger of  claim 11 , wherein the sintered material includes at least one of a sintered structure or a partial sintered structure. 
     
     
         20 . An apparatus comprising:
 a first heat exchanger manifold means;   a second heat exchanger manifold means;   a serpentine heat exchanger core means between the first heat exchanger manifold means and the second heat exchanger manifold means; and   a plurality of coolant fluid passage means extending along and in thermal conduction contact with at least a portion of the serpentine heat exchanger core means.