Header for high-pressure heat exchanger

1. A first header for a high-pressure heat exchanger, the header comprising:

a first high-pressure inlet configured to connect to a source of high-pressure fluid and through which the high-pressure fluid flows therethrough to enter the first header;

a first high-pressure tube extending from the high-pressure inlet to a first high-pressure transition section;

the first high-pressure transition section configured to divide the high-pressure fluid from the first high-pressure tube into multiple first high-pressure flow channels extending in an axial direction, the first high-pressure transition section having inlets of the multiple first high-pressure flow channels spaced from one another in a radial direction and collectively arranged in a substantially circular shape, the inlets of the multiple first high-pressure flow channels on a radially outer edge of the first high-pressure transition section being spaced further apart in a circumferential direction from adjacent inlets of the multiple first high-pressure flow channels than radially inward inlets are spaced from adjacent radially inward inlets of the multiple first high-pressure flow channels;

the multiple first high-pressure flow channels extending from the first high-pressure transition section to a second-high pressure transition section;

the second high-pressure transition section being adjacent a core of the heat exchanger and configured to divide each of the multiple first high-pressure flow channels into at least two first high-pressure sub-flow channels, the first high-pressure sub-flow channels being configured to connect to high-pressure flow passages of the core;

a low-pressure outlet configured to connect to a component able to accept low-pressure fluid;

a low-pressure tube extending from a first low-pressure transition section to the low-pressure outlet;

the first low-pressure transition section configured to merge the low-pressure fluid from multiple low-pressure flow channels into the low-pressure tube;

the second low-pressure transition section being adjacent the core and configured to merge at least two low-pressure sub-flow channels into each of the multiple low-pressure flow channels; and

the low-pressure sub-flow channels being configured to connect to low-pressure flow passages of the core.

2. The first header of claim 1 , wherein each flow channel of the first high-pressure flow channels and each sub-flow channel of the first high-pressure sub-flow channels have a round cross-sectional shape.

3. The first header of claim 1 , wherein each of the low-pressure sub-flow channels has a substantially diamond cross-sectional shape.

4. The first header of claim 2 , wherein the number of multiple low-pressure flow channels remains constant between the second low-pressure transition section and the first low-pressure transition section.

5. The first header of claim 2 , wherein the multiple first high-pressure flow channels, second high-pressure transition section, the first high-pressure sub-flow channels, the multiple low-pressure flow channels, the second low-pressure transition section, and the low-pressure sub-flow channels are all in a solid block.

6. The first header of claim 1 , wherein the low-pressure flow path changes direction forty-five degrees or less between the second low-pressure transition section and the first low-pressure transition section.

7. The first header of claim 1 , wherein the high-pressure fluid is at a pressure greater than approximately 300 bars (4350 psi).

8. The first header of claim 1 , wherein the low-pressure fluid is at a pressure greater than approximately 65 bars (950 psi).

9. The first header of claim 1 , wherein the round cross-sectional shape of each of the multiple first high-pressure flow channels and each of the first high-pressure sub-flow channels are circular.

10. The first header of claim 1 , wherein the multiple first high-pressure flow channels converge and then diverge between the first high-pressure transition section and the second high-pressure transition section.

11. The first header of claim 1 , wherein the multiple first high-pressure flow channels change direction forty-five degrees or less between the first high-pressure transition section and the second high-pressure transition section.

12. The first header of claim 1 , wherein the first high-pressure transition section is semi-ellipsoidal in a flow direction of the high-pressure fluid.

13. The first header of claim 1 , wherein the second high-pressure transition section is configured to divide each of the multiple first high-pressure flow channels into six first high-pressure sub-flow channels.

14. The first header of claim 1 , wherein the first high-pressure tube has a substantially circular cross-sectional shape.

15. A heat exchanger comprising:

the core having high-pressure flow passages and low-pressure flow passages; and

the first header of claim 1 connected to the core.

16. The heat exchanger of claim 15 , wherein the high-pressure flow passages have a substantially circular cross-sectional shape.

17. The heat exchanger of claim 15 , further comprising:

a second header configured to extend from the core to a component able to accept high-pressure fluid, the second header comprising:

a third high-pressure transition section adjacent to the core and configured to merge at least two second high-pressure sub-flow channels, which are configured to connect to high-pressure flow passages of the core, into one of multiple second high-pressure flow channels;

the multiple second high-pressure flow channels extend between the third high-pressure transition section and a fourth high-pressure transition section;

the fourth high-pressure transition section configured to merge the multiple second high-pressure flow channels extending in the axial direction into a second high-pressure tube, the fourth high-pressure transition section having outlets of the multiple second high-pressure flow channels spaced from one another in a radial direction and collectively arranged in a substantially circular shape, the outlets of the multiple second high-pressure flow channels on a radially outer edge of the fourth high-pressure transition section being spaced further apart in the circumferential direction from adjacent outlets of the multiple second high-pressure flow channels than radially inward outlets are spaced from adjacent radially inward outlets of the multiple second high-pressure flow channels;

a second high-pressure tube extending from the fourth high-pressure transition section to a high-pressure outlet;

the high-pressure outlet configured to connect to the component able to accept high-pressure fluid,

wherein each of the second high-pressure flow channels and each of the second high-pressure sub-flow channels have a round cross-sectional shape.

18. The heat exchanger of claim 17 , wherein the second header further comprises:

a second low-pressure flow path configured to extend from a source of low-pressure fluid to the core.

19. The heat exchanger of claim 17 , wherein the first header, the core, and the second header are one continuous and monolithic component constructed via additive manufacturing.

20. The first header of claim 1 , wherein the first high-pressure tube changes direction forty-five degrees or less between the first high-pressure inlet and the first high-pressure transition section.