Single phase micro/mini channel heat exchangers for gas turbine intercooling

A multi-width channel heat exchanger (MWCHX) system for a gas turbine engine, the MWCHX system comprising:

• a first MWCHX having an upper portion and a lower portion, the first MWCHX comprising:
• a first layer having a plurality of air-passage mini-channels configured to convey a first air stream through the first MWCHX in a first flow direction, wherein each air-passage mini-channel of the plurality air-passage mini-channels has an air-channel length and an air-channel width less than the air-channel length;
• a second layer bonded to the first layer, the second layer having a plurality of heat transfer fluid channels configured to convey a heat transfer fluid through the first MWCHX in a second flow direction opposite the first flow direction, wherein each heat transfer fluid channel of the plurality of heat transfer fluid channels has a heat transfer channel length and a heat transfer channel width less than the heat transfer channel length, and wherein the heat transfer channel width is less than the air-channel width;
• and
• a plurality of elongated sealing sets respectively including the plurality of heat transfer fluid channels and a plurality of sealing layers, the plurality of sealing layers being diffusion bonded to the plurality of heat transfer fluid channels, the plurality of elongated sealing sets spanning transverse to the air-channel length of the plurality of air-passage mini-channels, the plurality of elongated sealing sets being arranged in rows interposed by respective spaces to expose a portion of at least two rows of the plurality of air-passage mini-channels to the first air stream, and the plurality of air-passage mini-channels being substantially parallel with the plurality of heat transfer fluid channels,
• wherein the plurality of heat transfer fluid layers, the plurality of sealing layers, and the plurality of air-passage mini-channels extend between the upper portion and the lower portion and
• wherein the first flow direction of the first air stream in the plurality of air-passage mini-channels is substantially parallel with the second flow direction of the heat transfer fluid in the plurality of heat transfer fluid channels, and the plurality of air-passage mini-channels is arranged as air-passage layers in an annular arrangement about an engine axis.

A method of conveying a quantity of heat within a gas turbine engine comprising:

• passing a gas turbine engine air stream through a plurality of etched mini-channel air passages of a first heat exchanger in a first flow direction, wherein each passage of the plurality of etched mini-channel air passages has a first air-channel wall and a second air-channel wall at an air-channel distance from each other;
• and
• passing a heat transfer fluid through a plurality of etched heat transfer fluid passages of the first heat exchanger in a second flow direction opposite the first flow direction such that the quantity of heat is transferred between the heat transfer fluid and the air stream, wherein each passage of the plurality of etched heat transfer fluid passages has a first heat transfer channel wall and a second heat transfer channel wall at a heat transfer channel distance from each other, wherein the air-channel distance is greater than the heat transfer channel distance,
• wherein a plurality of elongated sealing sets respectively includes the plurality of etched heat transfer fluid passages and a plurality of sealing layers, the plurality of sealing layers is diffusion bonded to the plurality of etched heat transfer fluid passages, the plurality of elongated sealing sets span transverse to the passages of the plurality of etched mini-channel air passages, the plurality of elongated sealing sets is arranged in rows interposed by respective spaces to expose a portion of at least two rows of the plurality of etched mini-channel air passages to the air stream, and the plurality of etched mini-channel air passages is substantially parallel with the plurality of etched heat transfer fluid passages, and
• wherein the first flow direction of the first air stream in the plurality of etched air-passage mini-channels is substantially parallel with the second flow direction of the heat transfer fluid in the plurality of heat transfer fluid channels, and the plurality of etched air-passage mini-channels is arranged as air-passage layers in an annular arrangement about the engine axis.