Variable core heat exchanger with flow control

Abstract

A heat exchanger includes a core. The core includes a first layer and a second layer. The first layer includes a first plurality of fluid inlets. The second layer includes a second plurality of fluid inlets. The heat exchanger also includes a fluid header attached to the core adjacent the first plurality of fluid inlets and the second plurality of fluid inlets. The fluid header includes an inlet, an outlet, a plenum between the inlet and the outlet, and a flow control mechanism within the plenum. The flow control mechanism selectively directs fluid through the first plurality of fluid inlets, through the second plurality of fluid inlets, or through both the first plurality of fluid inlets and the second plurality of fluid inlets.

1 . A heat exchanger comprising:
 a core, wherein the core comprises:
 a first side; 
 a second side opposite the first side; 
 a third side extending from the first side to the second side; 
 a fourth side opposite the third side and extending from the first side to the second side; 
 a first layer comprising:
 a first plurality of primary fluid inlets on the first side of the core; and 
 a first plurality of primary fluid outlets on the second side of the core; 
 a first plurality of primary fluid passages extending from the first plurality of primary fluid inlets to the first plurality of primary fluid outlets; 
 a first plurality of secondary fluid inlets on the third side of the core; 
 a first plurality of secondary fluid outlets on the fourth side of the core; and 
 a first plurality of secondary fluid passages extending from the first plurality of secondary fluid inlets to the first plurality of secondary fluid outlets; and 
 
 a second layer comprising:
 a second plurality of primary fluid inlets on the first side of the core; 
 a second plurality of primary fluid outlets on the second side of the core; 
 a second plurality of primary fluid passages extending from the second plurality of primary fluid inlets to the second plurality of primary fluid outlets; 
 a second plurality of secondary fluid inlets on the third side of the core; and 
 a second plurality of secondary fluid outlets on the fourth side of the core; 
 a second plurality of secondary fluid passages extending from the second plurality of secondary fluid inlets to the second plurality of secondary fluid outlets; and 
 
   a primary fluid header attached to the first side of the core, wherein the primary fluid header comprises:
 an inlet; 
 a plenum; 
 an outlet; and 
 a flow control mechanism within the plenum, wherein the flow control mechanism selectively directs fluid through the first layer, through the second layer, or through both the first layer and the second layer. 
   
     
     
         2 . The heat exchanger of  claim 1 , wherein the first layer has a higher heat transfer rate than the second layer. 
     
     
         3 . The heat exchanger of  claim 2 , wherein the flow control mechanism is a three-way valve operating between a first position, a second position, and a third position. 
     
     
         4 . The heat exchanger of  claim 3 , wherein the three-way valve in the first position fluidically connects the inlet of the primary fluid header to the first plurality of primary fluid inlets while blocking fluidic communication between the inlet of the primary fluid header and the second plurality of primary fluid inlets, the three-way valve in the second position fluidically connects the inlet of the primary fluid header to the second plurality of primary fluid inlets while blocking fluidic communication between the inlet of the primary fluid header and the first plurality of primary fluid inlets, and the three-way valve in the third position fluidically connects the inlet of the primary fluid header to the first plurality of primary fluid inlets of the first layer and the second plurality of primary fluid inlets. 
     
     
         5 . The heat exchanger of  claim 4 , wherein the three-way valve further comprises:
 a plate, wherein the plate comprises:
 a first side facing the inlet of the primary fluid header; 
 a second side facing the outlet of the primary fluid header; and 
 a window, wherein the window extends through the first side and the second side of the plate; and 
   a torsional actuator mechanically coupled to the second side of the plate, wherein the torsional actuator rotates the plate to place the three-way valve in the first position, the second position, and the third position, and wherein the window enables fluidic communication between the inlet of the primary fluid header and the first plurality of primary fluid inlets and/or the second plurality of primary fluid inlets.   
     
     
         6 . The heat exchanger of  claim 5 , further comprising:
 a flow separator within the plenum of the primary fluid header extending between the second side of the flow control mechanism and the core, wherein the flow separator forms a first channel and a second channel inside the primary fluid header downstream from the plate, wherein the first channel extends from the plate to the first plurality of primary fluid inlets, and wherein the second channel extends from the plate to the second plurality of primary fluid inlets.   
     
     
         7 . The heat exchanger of  claim 2 , wherein the flow control mechanism is a baffle assembly, and wherein the baffle assembly comprises:
 a baffle extending from the first side of the core between the first layer and the second layer toward the inlet of the primary fluid header; and   an actuator mechanically attached to the baffle to operate the baffle between a first position, a second position, and a third position.   
     
     
         8 . The heat exchanger of  claim 7 , wherein the baffle comprises:
 a base end; and   a distal end opposite the base end, wherein a hinge attaches the base end of the baffle to the first side of the core.   
     
     
         9 . The heat exchanger of  claim 8 , wherein the actuator comprises:
 a rod;   at least one linkage arm attached to the rod by a first joint and attached to the distal end of the baffle by a second joint.   
     
     
         10 . The heat exchanger of  claim 9 , wherein the baffle in the first position fluidically connects the inlet of the primary fluid header to the first plurality of primary fluid inlets while blocking fluidic communication between the inlet of the primary fluid header and the second plurality of primary fluid inlets, the baffle in the second position fluidically connects the inlet of the primary fluid header to the second plurality of primary fluid inlets while blocking fluidic communication between the inlet of the primary fluid header and the first plurality of primary fluid inlets, and the baffle in the third position fluidically connects the inlet of the primary fluid header to the first plurality of primary fluid inlets of the first layer and the second plurality of primary fluid inlets. 
     
     
         11 . The heat exchanger of  claim 2 , wherein the flow control mechanism is a plate assembly, and wherein the plate assembly comprises:
 a plate located between the inlet of the primary fluid header and the first side of the core and extending perpendicular the first plurality of primary fluid inlets and the second plurality of primary fluid inlets; and   a linear actuator that moves the plate between a first position, a second position, and a third position.   
     
     
         12 . The heat exchanger of  claim 11 , wherein the plate in the first position blocks fluidic communication between the inlet of the primary fluid header and the second plurality of primary fluid inlets while allowing fluid communication between the inlet of the primary fluid header and the first plurality of primary fluid inlets, the plate in the second position blocks fluidic communication between the inlet of the primary fluid header and the first plurality of primary fluid inlets while allowing fluid communication between the inlet of the primary fluid header and the second plurality of primary fluid inlets, and the plate in the third position allows the first plurality of primary fluid inlets and the second plurality of primary fluid inlets to fluidically communicate with the inlet of the primary fluid header. 
     
     
         13 . The heat exchanger of  claim 2 , further comprising:
 a secondary fluid header attached to the third side of the core, wherein the secondary fluid header comprises:
 an inlet; 
 a plenum; and 
 a flow control mechanism within the plenum, wherein the flow control mechanism of the secondary fluid header selectively directs fluid through the first layer, through the second layer, or through both the first layer and second layer. 
   
     
     
         14 . The heat exchanger of  claim 13 , wherein the flow control mechanism of the secondary fluid header comprises one of:
 a three-way valve comprising:
 a plate, wherein the plate comprises:
 a first side facing the inlet of the secondary fluid header; 
 a second side facing the third side of the core; and 
 a window extending through the first side and the second side of the plate; and 
 
 a torsional actuator mechanically coupled to the second side of the plate, wherein the torsional actuator rotates the plate to change the orientation of the window, and wherein the window enables fluidic communication between the inlet of the secondary fluid header and the first plurality of secondary fluid inlets and/or the second plurality of secondary fluid inlets; 
   a baffle assembly comprising:
 a baffle extending from the third side of the core between the first layer and the second layer toward the inlet of the secondary fluid header and an actuator mechanically attached to the baffle to actuate the baffle, wherein baffle comprises a base end opposite a distal end, wherein a hinge attaches the base end of the baffle to the first side of the core, and wherein the actuator comprises at least one linkage arm attached to the distal end of the baffle; and 
   a plate assembly comprising:
 a plate located between the inlet of the secondary fluid header and the third side of the core extending perpendicular third side of the core and an actuator that moves the plate, 
   wherein the flow control mechanism of the secondary fluid header operates between a first position, a second position, and a third position.   
     
     
         15 . The heat exchanger of  claim 14 , wherein the flow control mechanism of the secondary fluid header in the first position fluidically connects the inlet of the secondary fluid header to the first plurality of secondary fluid inlets while blocking fluidic communication between the inlet of the secondary fluid header and the second plurality of secondary fluid inlets, the flow control mechanism in the second position fluidically connects the inlet of the secondary fluid header to the second plurality of secondary fluid inlets and blocks fluidic communication between the inlet of the secondary fluid header and the first plurality of secondary fluid inlets, and second control mechanism in the third position fluidically connects the inlet of the primary fluid header to the first plurality of secondary fluid inlets and the second plurality of secondary fluid inlets. 
     
     
         16 . A heat exchanger comprising:
 a core, wherein the core comprises:
 a first layer comprising:
 a first plurality of primary fluid inlets; 
 a first plurality of primary fluid outlets; 
 a first plurality of primary fluid passages extending from the first primary fluid inlets to the first primary fluid outlets; 
 a first plurality of secondary fluid inlets; 
 a first plurality of secondary fluid outlets; and 
 a first plurality of secondary fluid passages extending from the first secondary fluid inlets to the first secondary fluid outlets, wherein the first secondary fluid passages extend transverse the first primary fluid passages; 
 
 a second layer comprising:
 a second plurality of primary fluid inlets; 
 a second plurality of primary fluid outlets; 
 a second plurality of primary fluid passages extending from the second primary fluid inlets to the second primary fluid outlets, wherein the second primary fluid passages extend adjacent the first primary fluid passages; 
 a second plurality of secondary fluid inlets; 
 a second plurality of secondary fluid outlets; and 
 a second plurality of secondary fluid passages extending from the second secondary fluid inlets to the second secondary fluid outlets, wherein the second secondary fluid passages extend transverse the second primary fluid passages; and 
 
   a primary fluid header attached to the core adjacent the first plurality of primary fluid inlets and the second plurality of primary fluid inlets, wherein the primary fluid header comprises:
 an inlet; 
 an outlet; 
 a plenum between the inlet and the outlet; and 
 a flow control mechanism within the plenum, wherein the flow control mechanism selectively directs fluid through the first primary fluid inlets, through the second primary fluid inlets, or through both the first primary fluid inlet and the second primary fluid inlets. 
   
     
     
         17 . The heat exchanger of  claim 16 , wherein the first layer has a greater heat transfer rate than the second layer. 
     
     
         18 . The heat exchanger of  claim 17 , wherein the first primary fluid passages and the first secondary fluid passages are sinusoidal, and wherein the first primary fluid passages and the first secondary fluid passages comprise flow restriction elements that increase the heat transfer rate between the first primary fluid passages and the first secondary fluid passages. 
     
     
         19 . The heat exchanger of  claim 18 , wherein the flow control mechanism of the primary fluid header comprises one of the following:
 a three-way valve comprising:
 a plate, wherein the plate comprises:
 a first side facing the inlet of the primary fluid header; 
 a second side facing the outlet of the primary fluid header; and 
 a window, wherein the window extends through the first side and the second side of the plate; and 
 
 a torsional actuator mechanically coupled to the plate, wherein the torsional actuator rotates the plate to change the orientation of the window, and wherein the window enables fluidic communication between the inlet of the primary fluid header and the first primary fluid inlets and/or the second primary fluid inlets; 
   a baffle assembly comprising:
 a baffle extending from the core between the first layer and the second layer toward the inlet of the primary fluid header and an actuator mechanically attached to the baffle to actuate the baffle, wherein the baffle comprises a base end opposite a distal end, wherein a hinge attaches the base end of the baffle to the core, and wherein the actuator comprises at least one linkage arm attached to the distal end of the baffle; and 
   a plate assembly comprising:
 a plate located between the inlet of the primary header and the core extending perpendicular the first plurality of primary fluid inlets and the second plurality of primary fluid inlets; and 
 an actuator that moves the plate, 
   wherein the flow control mechanism of the primary fluid header operates between a first position, a second position, and a third position.   
     
     
         20 . The heat exchanger of  claim 19 , wherein the flow control mechanism in the first position fluidically connects the inlet of the primary fluid header to the first primary fluid inlets while blocking fluidic communication between the inlet of the primary fluid header and the second primary fluid inlets, the flow control mechanism in the second position fluidically connects the inlet of the primary fluid header to the second primary fluid inlets while blocking fluidic communication between the inlet of the primary fluid header and the first primary fluid inlets, and flow control mechanism in the third position fluidically connects the inlet of the primary fluid header to the first primary fluid inlets and the second primary fluid inlets.