Ultra-Compact Condenser with Built-in Air Flow Headers

Next-generation aircraft thermal management systems require advanced compact, lightweight condensers to reduce the overall size and mass of high-capacity vapor compression systems. To this end, Creare proposes to develop an ultra-compact, lamination-stack condenser with built-in air flow headers to substantially reduce the overall condenser assembly size and mass. The condenser has a unique configuration to simplify its integration with air ducts and thus minimize its installation envelope and mass. The condenser flow channels have features tailored along the flow direction to enhance the overall heat transfer while minimizing flow pressure drop increase. The proposed condenser assembly will achieve a volumetric heat capacity twice the current state-of-the-art condensers. In Phase I, we will first work with our OEM collaborator to identify a target application and develop design specifications. We will prove the feasibility of our approach by building and demonstrating a proof-of-concept subscale condenser, developing the Phase II condenser prototype design, and predicting its performance. In Phase II we will design, build, and demonstrate a laboratory condenser prototype under prototypical conditions and deliver the prototype to the Air Force for further performance evaluation.