Patent Description:
Typical heat exchangers are designed to provide a configuration in which a hot fluid can transfer thermal energy to a cold fluid. Usually, the hot and cold fluids are low-pressure fluids (e.g., fluids that have a pressure less than approximately <NUM> bars (<NUM> psi)). The heat exchanger, including the headers that direct the fluids into and out of the heat exchanger core, do not need to handle high pressures from the fluids. For example, the headers can include anywhere from tens to thousands of channels branching and merging to connect to a core that has tens to thousands of particularly shaped passages. Because the heat exchangers and the headers that direct the fluids into and out of the heat exchangers do not need to handle high-pressures from the fluids, intricate topologies can be used for the headers without the need for structural support of the header channels and also without the need for configurations that reduce stress and strain caused by the elevated pressure. Heat exchanger headers are known from <CIT>, <CIT>, <CIT> and <CIT>.

A first header for a high-pressure heat exchanger includes a first high-pressure inlet configured to connect to a source of high-pressure fluid and through which the high-pressure fluid flows therethrough to enter the first header, a first high-pressure tube extending from the high-pressure inlet to a first high-pressure transition section, and the first high-pressure transition section configured to divide the high-pressure fluid from the first high-pressure tube into multiple first high-pressure flow channels extending in an axial direction. The first high-pressure transition section has inlets for the multiple first high-pressure flow channels that are spaced from one another in a radial direction and collectively arranged in a substantially circular shape. The inlets for the multiple first high-pressure flow channels on a radially outer edge of the first high-pressure transition section are spaced further apart in a circumferential direction from adjacent inlets of the multiple first high-pressure flow channels than radially inward inlets are spaced from adjacent radially inward inlets of the multiple first high-pressure flow channels. The first header also includes multiple first high-pressure flow channels extending from the first high-pressure transition section to a second-high pressure transition section, and the second high-pressure transition section being adjacent a core of the heat exchanger and configured to divide each of the multiple first high-pressure flow channels into at least two first high-pressure sub-flow channels. The first high-pressure sub-flow channels are configured to connect to high-pressure flow passages of the core. Each flow channel of the multiple first high-pressure flow channels and each sub-flow channel of the first high-pressure sub-flow channels have a round cross-sectional shape. The first header also includes a low-pressure flow path configured to extend from the core to a component able to accept low-pressure fluid.

While the above-identified figures set forth embodiments of the present invention, other embodiments are also contemplated, as noted in the discussion. In all cases, this disclosure presents the invention by way of representation and not limitation. It should be understood that numerous other modifications and embodiments can be devised by those skilled in the art, which fall within the scope of the invention provided they are within the scope of the claims. The figures may not be drawn to scale, and applications and embodiments of the present invention may include features, steps and/or components not specifically shown in the drawings.

A header for a heat exchanger is disclosed herein that can accommodate at least one fluid that is under high pressure (greater than approximately <NUM> bars (<NUM> psi)). This header can direct a high-pressure fluid (e.g. approximately <NUM> bars (<NUM> psi)) and a relatively low-pressure fluid (e.g. approximately <NUM> bars (<NUM> psi)) into and/or out of the heat exchanger. The header can be a high-pressure inlet header with a high-pressure flow path inlet and a low-pressure flow path outlet. Analogously, a high-pressure outlet header with a high-pressure flow path outlet and a low-pressure flow path inlet can be mirrored in substantially the same configuration as the high-pressure inlet header. The following description is in regards to the high-pressure inlet header but also applies to the high-pressure outlet header (in a mirrored configuration).

The high-pressure inlet header includes a first high-pressure transition section extending in an axial direction (i.e., the direction of fluid flow) that transitions/divides the flow from a single high-pressure tube upstream to multiple high-pressure flow channels downstream. The first high-pressure transition section has inlets of the multiple high-pressure flow channels collectively arranged in a substantially circular shape. Outer inlets are spaced from one another in a radial direction with the outer inlets on a radially outer edge of the first high-pressure transition section being spaced further apart from adjacent outer inlets on the radially outer edge than radially inward inlets are spaced from adjacent radially inward inlets. Such a configuration of the spacing of inlets reduces stress concentrations on the first high-pressure transition section caused by the pressure of the high-pressure fluid and the flow of the high-pressure fluid.

The multiple high-pressure flow channels extend in the axial direction from the first high-pressure transition section to a second high-pressure transition section, which is adjacent a core of the heat exchanger. The second high-pressure transition section transitions/divides the flow from each flow channel of the multiple high-pressure flow channels into at least two, but up to sixteen, sub-flow channels that match high-pressure flow passages through the core. Along the high-pressure flow path (which includes the high-pressure tube, the first high-pressure transition section, the multiple high-pressure flow channels, the second high-pressure transition section, and the high-pressure sub-flow channels), the flow path has a round cross-sectional shape; such as a circle, oval, ellipse, etc.; to provide increased strength to handle the high pressures of the high-pressure fluid flowing therein.

The low-pressure flow path through the high-pressure inlet header can have a variety of configurations, including a low-pressure tube, a first low-pressure transition section, multiple low-pressure flow channels, a second low-pressure transition section, and low-pressure sub-flow channels that are similar in configuration to corresponding components of the high-pressure flow path.

The header described herein provides sufficient strength and stress distribution/reduction to accommodate a high-pressure fluid flowing therethrough and through the heat exchanger core. Additionally, the configuration of the first high-pressure transition section, multiple high pressure flow channels, and second high-pressure transition section are simpler and more economical to manufacture than the prior art headers that divide the flow multiple times along a large distance in the axial direction. The configurations of prior art headers could crack and/or leak when carrying high-pressure fluids, and thus would not be able to be used in a high-pressure environment. These and other advantages will be realized in the disclosure below.

<FIG> is a cross-sectional view of heat exchanger <NUM> having core <NUM>, high-pressure inlet header <NUM>, and high-pressure outlet header <NUM>. Heat exchanger <NUM> also includes high-pressure flow path <NUM> and low-pressure flow path <NUM>. Along high-pressure flow path <NUM>, high-pressure inlet header <NUM> includes high-pressure inlet <NUM> (configured to connect to high-pressure fluid source <NUM>), high-pressure tube <NUM>, and first high-pressure transition section <NUM> (not shown in <FIG> are multiple high-pressure flow channels, second high-pressure transition section, and high-pressure sub-flow channels). Along low-pressure flow path <NUM>, high-pressure inlet header <NUM> also includes low-pressure outlet <NUM> (configured to connect to low-pressure fluid component <NUM> that can accept low-pressure fluid), low-pressure tube <NUM>, low-pressure transition section <NUM>, multiple low-pressure flow channels <NUM>, second low-pressure transition section <NUM>, and low-pressure sub-flow channels <NUM>.

High-pressure outlet header <NUM> is configured similarly to high-pressure inlet header <NUM>. Along high-pressure flow path <NUM>, high-pressure outlet header <NUM> includes (not shown in <FIG> but similar to the components of high-pressure inlet header <NUM>) high-pressure sub-flow channels, a third high-pressure transition section, and multiple high-pressure flow channels. Also shown along high-pressure flow path <NUM>, high-pressure outlet header <NUM> includes fourth high-pressure transition section <NUM>, high-pressure tube <NUM>, and high-pressure outlet <NUM> (configured to connect to high-pressure fluid component <NUM> that is able to accept high-pressure fluid). Along low-pressure flow path <NUM>, high-pressure outlet header <NUM> also includes low-pressure sub-flow channels <NUM>, third low-pressure transition section <NUM>, multiple low-pressure flow channels <NUM>, fourth low-pressure transition section <NUM>, low-pressure tube <NUM>, and low-pressure inlet <NUM> (configured to connect to low-pressure fluid source <NUM>). Core <NUM> of heat exchanger <NUM> includes high-pressure flow passages <NUM> and low-pressure flow passages <NUM>.

Heat exchanger <NUM> is disclosed herein having the low-pressure fluid enter heat exchanger <NUM> at a greater temperature than the high-pressure fluid enters heat exchanger <NUM>. However, other configurations of heat exchanger <NUM> can have the high-pressure fluid entering heat exchanger <NUM> at a greater temperature than the low-pressure fluid enters heat exchanger <NUM>. Additionally, heat exchanger <NUM> can include other features, characteristics, and/or configurations not expressly disclosed. Core <NUM> can have any configuration suitable for transferring thermal energy between the two fluids flowing through heat exchanger <NUM>. For example, core <NUM> can have a generally rectangular cross-sectional shape. Core <NUM> can undulate (e.g., have waves) or extend straight in a flow direction, and high-pressure flow passages <NUM> and low-pressure flow passages <NUM> extending in opposite flow directions through core <NUM> can have any shape. In one embodiment, high-pressure flow passages <NUM> each have a circular cross-sectional shape and low-pressure flow passages <NUM> each have a substantially diamond cross-sectional shape situated between high-pressure flow passages <NUM>.

High-pressure flow path <NUM> extends from high-pressure inlet <NUM> to high-pressure outlet <NUM> and conveys the high-pressure fluid from high-pressure fluid source <NUM> to high-pressure fluid component <NUM>. Similarly, low-pressure flow path <NUM> extends in a generally opposite direction to high-pressure flow path <NUM> from low-pressure fluid source <NUM> to low-pressure fluid component <NUM>. However, in other embodiments, high-pressure fluid flow path <NUM> can be in generally the same direction as low-pressure flow path <NUM>.

High-pressure inlet header <NUM> is an upstream portion of high-pressure flow path <NUM> and a downstream portion of low-pressure flow path <NUM>. As discussed above, high-pressure inlet header <NUM> has the same configuration as high-pressure outlet header <NUM> except that high-pressure outlet header <NUM> is mirrored in substantially the same configuration as high-pressure inlet header <NUM>. Thus, any discussion below with regards to high-pressure inlet header <NUM> also applies to high-pressure outlet header <NUM> except that any inlets for high-pressure inlet header <NUM> are outlets for high-pressure outlet header <NUM> and vice versa.

High-pressure inlet header <NUM> includes a high-pressure side and a low-pressure side. High-pressure tube <NUM> receives high-pressure fluid from high-pressure fluid source <NUM> through high-pressure inlet <NUM>. High-pressure tube <NUM> can have any size, shape, and/or configuration suitable for conveying high-pressure fluid from high-pressure fluid source <NUM> to first high-pressure transition section <NUM>. In one embodiment, high-pressure tube <NUM> is a single channel having a circular cross-sectional shape. High-pressure tube <NUM> can extend straight or can have a curve, turn, or another configuration that changes the direction of the flow. In <FIG>, high-pressure tube <NUM> has a curve of approximately forty-five degrees measured from a flow direction through core <NUM>. High-pressure tube <NUM> can have a constant cross-sectional shape/area or can have a varying cross-sectional shape/area with stair steps or other features. Low-pressure tube <NUM> of high-pressure inlet header <NUM> and high-pressure tube <NUM> and low-pressure tube <NUM> of high-pressure outlet header <NUM> can each have similar shapes, sizes, and/or configurations of high-pressure tube <NUM> of high-pressure inlet header <NUM>. For example, the curve of low-pressure tube <NUM> can have a curve of approximately forty-five degrees measured from a flow direction through core <NUM> such that the total difference in flow direction of high-pressure fluid in high-pressure tube <NUM> near first high-pressure transition section <NUM> and low-pressure fluid in low-pressure tube <NUM> near first low-pressure transition section <NUM> is approximately ninety degrees. A similar configuration can be present in high-pressure outlet header <NUM>.

For clarity, <FIG> does not show the entirety of high-pressure flow path <NUM>, and only shows high-pressure tubes <NUM> and <NUM> connected to first high-pressure transition section <NUM> and fourth high-pressure transition section <NUM>, respectively. Other components of high-pressure flow path <NUM>; such as the multiple high-pressure flow channels, the second high-pressure transition section, and the high-pressure sub-flow channels; are shown in <FIG> and described below. However, <FIG> does show high-pressure tube <NUM> connected to first high-pressure transition section <NUM> to transition/divide high-pressure fluid from a single channel to the multiple high-pressure flow channels. Similarly, high-pressure tube <NUM> is connected to fourth high-pressure transition section <NUM> to transition/merge high-pressure fluid from the multiple high-pressure flow channels in high-pressure outlet header <NUM> to a single channel of high-pressure tube <NUM>.

<FIG> shows the entirety of low-pressure flow path <NUM> extending between low-pressure fluid source <NUM> (connected to high-pressure outlet heater <NUM>) and low-pressure fluid component <NUM> (connected to high-pressure inlet header <NUM>). Low-pressure flow path <NUM> can be similar in configuration and components to high-pressure flow path <NUM> but in an opposite direction. Low-pressure fluid enters heat exchanger <NUM> through low-pressure inlet <NUM>, through which low-pressure fluid flows into low-pressure tube <NUM> of high-pressure outlet header <NUM>. Low-pressure tube <NUM> can have the same shape, size, and/or configuration as high-pressure tubes <NUM> and <NUM> or can differ. Low-pressure fluid then flows from low-pressure tube <NUM> into fourth low-pressure transition section <NUM>, which transitions/divides the low-pressure fluid into multiple low-pressure flow channels <NUM>. Multiple low-pressure flow channels <NUM> extend substantially parallel to one another from fourth low-pressure transition section <NUM> to third low-pressure transition section <NUM>. Multiple low-pressure flow channels <NUM> can extend straight or can curve, turn, or otherwise change direction. As shown in <FIG>, multiple low-pressure flow channels <NUM> (and <NUM>) curve to change the direction of low-pressure fluid flow approximately forty-five degrees.

At third low-pressure transition section <NUM>, the low-pressure fluid is transitioned/divided again into at least two low-pressure sub-flow channels <NUM> for each flow channel of the multiple low-pressure flow channels <NUM>. In some embodiments, each flow channel of the multiple low-pressure flow channels <NUM> are divided at third low-pressure transition section <NUM> into more than two low-pressure sub-flow channels <NUM>, such as four, six, nine, or sixteen sub-flow channels. Additionally, adjacent flow channels of the multiple low-pressure flow channels <NUM> within third low-pressure transition section <NUM> can divide the flow into a different number of low-pressure sub-flow channels <NUM>. Also, third low-pressure transition section <NUM> can transition the shape of each flow channel from, for example, a circular cross-sectional shape of multiple low-pressure flow channels <NUM> to a diamond cross-sectional shape of low-pressure sub-flow channels <NUM>. After being divided at third low-pressure transition section <NUM>, the low-pressure fluid flows through low-pressure sub-flow channels <NUM> into core <NUM>.

After exiting core <NUM>, the low-pressure fluid flows through high-pressure inlet header <NUM> in a similar manner as high-pressure outlet header <NUM> but in an opposite direction. Thus, the low-pressure fluid flows into low-pressure sub-flow channels <NUM> and then is merged into multiple low-pressure flow channels <NUM> by second low-pressure transition section <NUM>. Multiple low-pressure flow channels <NUM> then extend (and possibly curve the low-pressure fluid flow) to first low-pressure transition section <NUM>, which transitions/merges the low-pressure fluid into one single channel of low-pressure tube <NUM>. Low-pressure tube <NUM> connects to low-pressure fluid component <NUM>, allowing the low-pressure fluid to flow out of heat exchanger <NUM> either at an elevated temperature than when low-pressure fluid entered heat exchanger <NUM> or at a lower temperature than when low-pressure fluid entered heat exchanger <NUM>, depending on the design and thermal energy transfer needs of heat exchanger <NUM>.

As shown in <FIG>, high-pressure flow path <NUM> and low-pressure flow path <NUM> are distant from one another at high-pressure inlet <NUM> and low-pressure outlet <NUM> (in high-pressure inlet header <NUM>) and at high-pressure outlet <NUM> and low-pressure inlet <NUM> (in high-pressure outlet header <NUM>) due to the curves in high-pressure tubes <NUM> and <NUM>, low-pressure tubes <NUM> and <NUM>, the multiple high-pressure flow channels, and multiple low-pressure flow channels <NUM> and <NUM>. However, heat exchanger <NUM> can have other configurations not expressly disclosed herein. For example, headers <NUM> and <NUM> can have other degrees of curves/turns or can be straight. Additionally, the high-pressure side and low-pressure sides of headers <NUM> and <NUM> do not need to extend away from each other such that high-pressure inlet <NUM> and low-pressure outlet <NUM> (and low-pressure inlet <NUM> and high-pressure outlet <NUM>) can be adjacent to one another.

<FIG> is a cross-sectional view of a portion of high-pressure inlet header <NUM> showing low-pressure flow path <NUM> as set out by box A in <FIG>, <FIG> is a cross-sectional view of a portion of high-pressure inlet header <NUM> showing the multiple high-pressure flow channels, <FIG> is a different cross-sectional view of a portion of high-pressure inlet header, and <FIG> are cross-sectional views of a portion of a second high-pressure transition section.

Shown in <FIG> is high-pressure inlet header <NUM> having high-pressure flow path <NUM> with high-pressure inlet <NUM>, high-pressure tube <NUM>, first high-pressure transition section <NUM>, multiple high-pressure flow channels <NUM>, second high-pressure transition section <NUM>, and high-pressure sub-flow channels <NUM>. Additionally, high-pressure inlet header <NUM> has low-pressure flow path <NUM> with low-pressure outlet <NUM> (not shown), low-pressure tube <NUM>, first low-pressure transition section <NUM>, multiple low-pressure flow channels <NUM>, second low-pressure transition section <NUM>, and low-pressure sub-flow channels <NUM>. While <FIG> show high-pressure inlet header <NUM>, high-pressure outlet header <NUM> can have the same components, sizes, configurations, etc., except that high-pressure outlet header <NUM> has a mirrored configuration than that of high-pressure inlet header <NUM> and provides an inlet for low-pressure fluid and an outlet for high-pressure fluid.

<FIG> shows an enlarged cross-sectional view of a portion of low-pressure tube <NUM> and each of first low-pressure transition section <NUM>, multiple low-pressure flow channels <NUM>, second low-pressure transition section <NUM>, and low-pressure sub-flow channels <NUM>. Low-pressure passages <NUM> of core <NUM> (not shown) each connect to one low-pressure sub-flow channel <NUM>. At second low-pressure transition section <NUM>, low-pressure sub-flow channels <NUM> converge into multiple low-pressure flow channels <NUM>. Also at second low-pressure transition section <NUM>, the cross-sectional shape of the flow/sub-flow channels can change, for example, from a diamond cross-sectional shape of low-pressure sub-flow channels <NUM> to a circular cross-sectional shape of multiple low-pressure flow channels <NUM>.

Multiple low-pressure flow channels <NUM> can extend substantially parallel and, as shown in <FIG>, curve to change the direction of multiple low-pressure flow channels <NUM> approximately forty-five degrees between second low-pressure transition section <NUM> and first low-pressure transition section <NUM>. At first low-pressure transition section <NUM>, multiple low-pressure flow channels <NUM> converge into one single low-pressure tube <NUM>. First low-pressure transition section <NUM> can have a circular cross-sectional shape similar to first high-pressure transition section <NUM> or can have another configuration suitable for converging multiple low-pressure flow channels <NUM> into one single low-pressure tube <NUM>.

<FIG> and <FIG> show a portion of high-pressure flow path <NUM> with high-pressure tube <NUM>, first high-pressure transition section <NUM>, multiple high-pressure flow channels <NUM>, second high-pressure transition section <NUM>, and high-pressure sub-flow channels <NUM>. High-pressure tube <NUM> has a circular cross-sectional shape and extends from high-pressure inlet <NUM> to first high-pressure transition section <NUM>. High-pressure tube <NUM> can extend straight or curve, turn, or otherwise change direction. In the disclosed embodiment, high-pressure tube <NUM> curves approximately forty-five degrees.

High-pressure tube <NUM> connects to first high-pressure transition section <NUM>, which divides the high-pressure fluid flow from a single, circular flow into multiple high-pressure flow channels <NUM> extending in an axial direction. First high-pressure transition section <NUM> has multiple inlets for multiple high-pressure flow channels <NUM> spaced from other inlets in a radial direction to collectively arrange the multiple inlets in a substantially circular shape. The inlets of multiple high-pressure flow channels <NUM> are arranged into outer inlets 74A on a radially outer edge of first high-pressure transition section <NUM> and inner inlets 74B radially inward from outer inlets 74A. Outer inlets 74A are spaced further apart from adjacent outer inlets 74A than inner inlets 74B are spaced from adjacent inner inlets 74B. Such a configuration of spacing of outer inlets 74A and inner inlets 74B reduces stress concentrations on first high-pressure transition section <NUM> caused by the elevated pressure of the high-pressure fluid. First high-pressure transition section <NUM>, as shown in <FIG>, has a semi-ellipsoidal shape in the flow direction (i.e., the axial direction) such that outer inlets 74A are tapered in the radial direction and inner inlets 74B can be tapered or are flat in a radial direction. Such a configuration also reduces stress concentrations.

Multiple high-pressure flow channels <NUM> extend from first high-pressure transition section <NUM> to second high-pressure transition section <NUM>. Multiple high-pressure flow channels <NUM> can extend substantially parallel and, as shown in <FIG>, curve to change the direction of multiple high-pressure flow channels <NUM> approximately forty-five degrees between first high-pressure transition section <NUM> and second high-pressure transition section <NUM>. Each flow channel of the multiple high-pressure flow channels <NUM> can have a variety of cross-sectional shapes, including a round cross-sectionals shape, such as a circle, oval, ellipse, etc. In one embodiment, each flow channel of the multiple high-pressure flow channels <NUM> are independent from one another and do not converge or diverge between first high-pressure transition section <NUM> and second high-pressure transition section <NUM> (i.e., the number of multiple high-pressure flow channels <NUM> remains constant). Another embodiment, shown and discussed with regards to <FIG> below, can include multiple high-pressure flow channels <NUM> that converge and then diverge again between first high-pressure transition section <NUM> and second high-pressure transition section <NUM>. Each flow channel of the multiple high-pressure flow channels <NUM> can have different sizes, shapes, and/or configurations from adjacent flow channels.

Multiple high-pressure flow channels <NUM> extend to second high-pressure transition section <NUM>, where each flow channel diverges into high-pressure sub-flow channels <NUM>. <FIG> shows one of the multiple high-pressure flow channels <NUM> extending to second high-pressure transition section <NUM>, and <FIG> shows high-pressure sub-flow channels <NUM> that have diverged from the one flow channel shown in <FIG>. As shown in the embodiment of <FIG>, second high-pressure transition section <NUM> divides the flow of each of the multiple high-pressure flow channels <NUM> horizontally and vertically to form six sub-flow channels per flow channel. These channels/sub-flow channels can continue to have a substantially circular cross-sectional shape through second high-pressure transition section <NUM>. While shown as diverging into six sub-flow channels, second high-pressure transition section <NUM> can divide the flow of each flow channel of the multiple high-pressure flow channels <NUM> into any number of high-pressure sub-flow channels <NUM>, such as two, four, nine, and sixteen sub-flow channels. Additionally, adjacent flow channels can be divided by second high-pressure transition section <NUM> into different numbers of sub-flow channels. High-pressure sub-flow channels <NUM> connect to core <NUM> and correspond to each passage of the high-pressure passages <NUM>.

High-pressure inlet header <NUM> can be constructed such that multiple high-pressure flow channels <NUM>, second high-pressure transition section <NUM>, high-pressure sub-flow channels <NUM>, multiple low-pressure flow channels <NUM>, second low-pressure transition section <NUM>, and low-pressure sub-flow channels <NUM> are all one continuous and monolithic piece contained in a solid block of material. This configuration may be accomplished by constructed high-pressure inlet header <NUM> via additive manufacturing and/or constructing the entirety of heat exchanger <NUM> via additive manufacturing.

<FIG> is a cross-sectional view of a portion of one embodiment of high-pressure inlet header <NUM> showing multiple high-pressure flow channels <NUM> converging and diverging between first high-pressure transition section <NUM> and second high-pressure transition section <NUM>. To reduce stress concentrations in high-pressure inlet header <NUM>, it may be advantageous for multiple high-pressure flow channels <NUM> to converge at junction 168A and then diverge again before second high-pressure transition section <NUM>. The number of flow channels of high-pressure flow channels <NUM> downstream of junction 168A (after diverging) can be the same number as before junction 168A (before converging), can be fewer flow channels than before junction 168A, or (as shown in <FIG>), can be more flow channels than before junction 168A. The cross-sectional shape of each flow channel of the multiple high-pressure flow channels <NUM> can be constant or can vary, such as being constricted before junction 168A and enlarged after junction 168A.

Heat exchanger <NUM> can include other components, features, characteristics, and/or configurations not expressly disclosed herein. Additionally, core <NUM> and headers <NUM>/<NUM> and <NUM> can have a variety of other configurations and features suitable for handling the elevated pressures of the high-pressure fluid while adequately transferring thermal energy between the high-pressure fluid and the low-pressure fluid.

Headers <NUM> and <NUM> described herein provide sufficient strength and stress distribution/reduction to accommodate a high-pressure fluid flowing therethrough and through heat exchanger <NUM>. Additionally, the configurations of first high-pressure transition section <NUM>, multiple high pressure flow channel <NUM>, and second high-pressure transition section <NUM> are simpler and more economical to manufacture than prior art headers that divide flow multiple times across multiple stages distributed along a large distance in the axial/flow direction. The configurations of prior art headers cannot reliably accommodate high-pressure fluids (the prior art headers would crack and leak), and thus would not be able to be used in a high-pressure environment.

Any relative terms or terms of degree used herein, such as "substantially", "essentially", "generally", "approximately" and the like, should be interpreted in accordance with and subject to any applicable definitions or limits expressly stated herein. In all instances, any relative terms or terms of degree used herein should be interpreted to broadly encompass any relevant disclosed embodiments as well as such ranges or variations as would be understood by a person of ordinary skill in the art in view of the entirety of the present disclosure, such as to encompass ordinary manufacturing tolerance variations, incidental alignment variations, transient alignment or shape variations induced by thermal, rotational or vibrational operational conditions, and the like. Moreover, any relative terms or terms of degree used herein should be interpreted to encompass a range that expressly includes the designated quality, characteristic, parameter or value, without variation, as if no qualifying relative term or term of degree were utilized in the given disclosure or recitation.

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

The low-pressure flow path includes a low-pressure outlet configured to connect to the component able to accept low-pressure fluid, a low-pressure tube extending from a first low-pressure transition section to the low-pressure outlet, the first low-pressure transition section configured to merge the low-pressure fluid from multiple low-pressure flow channels into the low-pressure tube, the multiple low-pressure flow channels extending from a second low-pressure transition section to the first low-pressure transition section, the second low-pressure transition section being adjacent the core and configured to merge at least two low-pressure sub-flow channels into each of the multiple low-pressure flow channels, and the low-pressure sub-flow channels being configured to connect to low-pressure flow passages of the core.

Each of the low-pressure sub-flow channels has a substantially diamond cross-sectional shape.

The number of multiple low-pressure flow channels remains constant between the second low-pressure transition section and the first low-pressure transition section.

The multiple first high-pressure flow channels, second high-pressure transition section, the first high-pressure sub-flow channels, the multiple low-pressure flow channels, the second low-pressure transition section, and the low-pressure sub-flow channels are all in a solid block.

The low-pressure flow path changes direction forty-five degrees or less between the second low-pressure transition section and the first low-pressure transition section.

The high-pressure fluid is at a pressure greater than approximately <NUM> bars (<NUM> psi).

The low-pressure fluid is at a pressure greater than approximately <NUM> bars (<NUM> psi).

The round cross-sectional shape of each of the multiple first high-pressure flow channels and each of the first high-pressure sub-flow channels are circular.

The multiple first high-pressure flow channels converge and then diverge between the first high-pressure transition section and the second high-pressure transition section.

The multiple first high-pressure flow channels change direction forty-five degrees or less between the first high-pressure transition section and the second high-pressure transition section.

The first high-pressure transition section is semi-ellipsoidal in a flow direction of the high-pressure fluid.

The second high-pressure transition section is configured to divide each of the multiple first high-pressure flow channels into six first high-pressure sub-flow channels.

The first high-pressure tube has a substantially circular cross-sectional shape.

A heat exchanger that includes the core having high-pressure flow passages and low-pressure flow passages and the first header connected to the core.

The high-pressure flow passages have a substantially circular cross-sectional shape.

A second header configured to extend from the core to a component able to accept high-pressure fluid that includes a third high-pressure transition section adjacent to the core and configured to merge at least two second high-pressure sub-flow channels, which are configured to connect to high-pressure flow passages of the core, into one of multiple second high-pressure flow channels; the multiple second high-pressure flow channels extend between the third high-pressure transition section and a fourth high-pressure transition section; the fourth high-pressure transition section configured to merge the multiple second high-pressure flow channels extending in the axial direction into a second high-pressure tube, the fourth high-pressure transition section having outlets of the multiple second high-pressure flow channels spaced from one another in a radial direction and collectively arranged in a substantially circular shape, the outlets of the multiple second high-pressure flow channels on a radially outer edge of the fourth high-pressure transition section being spaced further apart in the circumferential direction from adjacent outlets of the multiple second high-pressure flow channels than radially inward outlets are spaced from adjacent radially inward outlets of the multiple second high-pressure flow channels; a second high-pressure tube extending from the fourth high-pressure transition section to a high-pressure outlet; the high-pressure outlet configured to connect to the component able to accept high-pressure fluid, wherein each of the second high-pressure flow channels and each of the second high-pressure sub-flow channels have a round cross-sectional shape.

The second header further includes a second low-pressure flow path configured to extend from a source of low-pressure fluid to the core.

The first header, the core, and the second header are one continuous and monolithic component constructed via additive manufacturing.

The first high-pressure tube changes direction forty-five degrees or less between the first high-pressure inlet and the first high-pressure transition section.

Claim 1:
A first header for a high-pressure heat exchanger, the header comprising:
a first high-pressure inlet (<NUM>) configured to connect to a source of high-pressure fluid and through which the high-pressure fluid flows therethrough to enter the first header;
a first high-pressure tube (<NUM>) extending from the high-pressure inlet to a first high-pressure transition section;
the first high-pressure transition section (<NUM>) configured to divide the high-pressure fluid from the first high-pressure tube into multiple first high-pressure flow channels (<NUM>) extending in an axial direction, the first high-pressure transition section having inlets of the multiple first high-pressure flow channels spaced from one another in a radial direction and collectively arranged in a substantially circular shape, the inlets of the multiple first high-pressure flow channels on a radially outer edge of the first high-pressure transition section being spaced further apart in a circumferential direction from adjacent inlets of the multiple first high-pressure flow channels than radially inward inlets are spaced from adjacent radially inward inlets of the multiple first high-pressure flow channels;
the multiple first high-pressure flow channels extending from the first high-pressure transition section to a second high-pressure transition section (<NUM>);
the second high-pressure transition section being configured to be adjacent to a core (<NUM>) of the heat exchanger and configured to divide each of the multiple first high-pressure flow channels into at least two first high-pressure sub-flow channels (<NUM>), the first high-pressure sub-flow channels being configured to connect to high-pressure flow passages of the core,
wherein each flow channel of the first high-pressure flow channels and each sub-flow channel of the first high-pressure sub-flow channels have a round cross-sectional shape; and
a low-pressure flow path (<NUM>) configured to extend from the core to a component able to accept low-pressure fluid.