Ultra-Compact Heat Exchangers

Makai Ocean Engineering, Inc. proposes to address thermal management performance shortfalls for 6th generation air platforms by developing a novel heat exchanger technology. Specifically, Makai will develop an ultra-compact thin-foil heat exchanger (TFHX) for air-cooled, two-phase vapor cycle systems. The TFHX will provide at least a 50% improvement in volumetric performance, pressure drops of less than 1psi, and lower weights compared to the current state-of-the-art. The TFHX manufacturing process uses advanced and high-precision techniques that enable use of thin foils (0.0015 inch), custom flow geometries, surface enhancements, elimination of backing plates and tension rods, and most importantly enabling irregular and non-rectilinear heat exchanger volume envelopes. Computational fluid dynamics (CFD) simulations show air-convection coefficients of at least 350 W/m2-K. Combined with surface area densities of 2000 m2/m3, this meets and exceeds specifications set by Lockheed Martin and Honeywell. Makai will work with LM Aero to mature the TFHX to TRL 6 for use in irregular, peripheral spaces in the air platform, which is not possible with current state-of-the-art units. Prototype plates have been pressure tested to over 375 psi at Makai’s facility in Hawaii, making this a relatively low-risk development and shortening the transition timeline for the USAF.