Low-Cost Compact Microchannel Heat Exchanger With Uniform Flow Distribution

Increasing use of high power density electronics systems in military vehicles and buildings will significantly increase thermal loads of their Environmental Control Systems (ECS). Advanced thermal management technology is needed for these ECSs. We propose to develop a highly effective, low-cost heat exchanger that will enhance thermal effectiveness of evaporators in vapor compression systems. The heat exchanger has design features to effectively suppress flow instability in the evaporator under challenging operating conditions, thus significantly enhancing its thermal effectiveness and the ECS power efficiency. The compact microchannel heat exchanger will also significantly reduce the size and mass of the evaporator. The fabrication of the heat exchanger is built on well-established manufacturing techniques for modern large-scale heat exchangers. In Phase I, we will prove the feasibility of the microchannel heat exchanger through laboratory testing and design the Phase II laboratory-scale microchannel heat exchanger. In Phase II, we will design, build, and demonstrate a highly effective microchannel heat exchanger for an ECS.