Open Cell Foam Metal Heat Exchanger

Abstract

A method of enhancing an open celled foam metal heat exchanger is presented where the structure uses fluid channels that distribute fluid and/or air across a continuous flow field. The heat exchanger not only improves heat transfer properties given a required pressure drop but also takes into consideration the need to manufacture low cost solutions that may be mass produced to meet high capacity throughput requirements for the air and space industries.

1 . An open celled foam metal counter flow heat exchanger comprising
 a. an impermeable housing container; and   b. a combination of at least two adjacent panels, each panel comprising
 i. an impermeable base; 
 ii. a field of open celled foam metal comprising cells comprised of ligaments and pores; 
 iii. a fluid inlet; 
 iv. a fluid outlet; and 
 v. optionally, at least one fluid channel. 
   
     
     
         2 . The open celled foam metal counter flow heat exchanger according to  claim 1 , wherein each panel has the fluid inlet located on the same end as the adjacent panel. 
     
     
         3 . The open celled foam metal counter flow heat exchanger according to  claim 1 , wherein each panel has the fluid outlet located on the same end as the adjacent panel. 
     
     
         4 . The open celled foam metal counter flow heat exchanger according to  claim 1 , wherein each panel has the fluid inlet located on the opposite end as the adjacent panel. 
     
     
         5 . The open celled foam metal counter flow heat exchanger according to  claim 1 , wherein each panel has the fluid outlet located on the opposite end as the adjacent panel. 
     
     
         6 . The open celled foam metal counter flow heat exchanger according to  claim 1 , wherein the field of open celled foam metal has ligament geometry to enhance turbulent and laminar fluid flow. 
     
     
         7 . The open celled foam metal counter flow heat exchanger according to  claim 1 , wherein the open celled foam metal has 40 pores per inch (PPI) and 7-8% relative density and is compressible. 
     
     
         8 . The open celled foam metal counter flow heat exchanger according to  claim 1 , wherein the open celled foam metal is DUOCEL®. 
     
     
         9 . A method of making the open celled foam metal counter flow heat exchanger according to  claim 1  comprising combining fluid flow fields to create improved heat transfer performance. 
     
     
         10 . A method of using the open celled foam metal counter flow heat exchanger according to  claim 1  comprising
 a. inserting a first liquid into a first panel of the combination; 
 b. moving the first liquid through the field of open celled foam metal and removing the first liquid from the first panel; 
 c. inserting a second liquid into a second panel of the combination; 
 d. moving the second liquid through the field of open celled foam metal; and 
 e. removing the second liquid from the second panel, 
 
       wherein the flow of the second liquid is in the opposite direction as the flow of the first liquid and wherein heat has been exchanged between the first liquid and the second liquid. 
     
     
         11 . The method of using the open celled foam metal counter flow heat exchanger according to  claim 10 , wherein the combination comprises the first panel adjacent to the second panel. 
     
     
         12 . The method of using the open celled foam metal counter flow heat exchanger according to  claim 10 , wherein the combination comprises a series of first and second panels. 
     
     
         13 . The method of using the open celled foam metal counter flow heat exchanger according to  claim 10 , wherein the first liquid is a cool liquid and the second liquid is a hot liquid. 
     
     
         14 . The method of using the open celled foam metal counter flow heat exchanger according to  claim 10 , wherein the first liquid is fuel and the second liquid is oil.