Abstract: A tubular array heat exchanger and a method of manufacturing the same are provided. The heat exchanger includes a plurality of tubes extending between a tube inlet and a tube outlet. An inlet manifold includes an inner wall and an outer wall defining an inlet plenum and one or more baffles extending between the inner wall and the outer wall to divide the inlet plenum into a plurality of fluid passageways, each of the plurality of fluid passageways extending between the inlet plenum and a respective one of the tube inlets. The tubes, the inlet manifold, and an outlet manifold identical to the inlet manifold are manufactured as a single monolithic component.

Abstract: A heat exchanger includes a heat exchanger core, a header defining a header manifold, and a transition portion that provides fluid communication between the heat exchanger core and the header manifold. The transition portion includes a transition tube extending between the header and the heat exchanger core, a header junction where the transition tube joins the header, and a splitting junction that splits the transition tube into the plurality of heat exchange tubes. The header junction may define elliptical inlet apertures, a large filleted joint, and a junction thickness that is greater than a header wall thickness.

Abstract: A header for a heat exchanger includes a first barrel and a second barrel stacked on top of each other and being separated by a septum which may include one or more apertures. The first barrel and the second barrel may define a first manifold and a second manifold, respectively, which may be in fluid communication via the apertures in the septum. An inlet manifold is in fluid communication with the first manifold and the second manifold for providing a flow of heated fluid, the heated fluid being distributed through the first manifold and the second manifold before passing through a plurality of heat exchange tubes that extend from each of the first manifold and the second manifold.

Abstract: A heat exchanger includes a heat exchanger core, a header defining a header manifold, and a transition portion that provides fluid communication between the heat exchanger core and the header manifold. The transition portion includes a transition tube extending between the header and the heat exchanger core, a header junction where the transition tube joins the header, and a splitting junction that splits the transition tube into the plurality of heat exchange tubes. The header junction may define elliptical inlet apertures, a large filleted joint, and a junction thickness that is greater than a header wall thickness.

Abstract: A tubular array heat exchanger and a method of manufacturing the same are provided. The heat exchanger includes a plurality of helical tubes defining a primary diameter around the centerline to define interstitial voids between the plurality of tubes. The plurality of tubes defines an increased surface area compared to a single heat transfer tube having the same primary diameter, thereby resulting in improved heat transfer efficiency or a smaller footprint. In addition, the helically formed tubes and optional stiffening structures improve the structural resiliency of the heat exchanger to better absorb thermal expansion and contraction with improved modal response.

Abstract: A tubular array heat exchanger and a method of manufacturing the same are provided. The heat exchanger includes a plurality of tubes extending between a tube inlet and a tube outlet. An inlet manifold includes an inner wall and an outer wall defining an inlet plenum and one or more baffles extending between the inner wall and the outer wall to divide the inlet plenum into a plurality of fluid passageways, each of the plurality of fluid passageways extending between the inlet plenum and a respective one of the tube inlets. The tubes, the inlet manifold, and an outlet manifold identical to the inlet manifold are manufactured as a single monolithic component.