Heat engine with cooled cooling air heat exchanger system

Abstract

A gas turbine engine comprises: a fan assembly; a core engine, which is arranged downstream of the fan assembly and includes a core engine casing, a compressor section downstream of the fan assembly, a combustion section downstream of the compressor section, and a turbine section downstream of the combustion section; a fan bypass airflow path, which is arranged downstream of the fan assembly and outside the core engine casing; a core flow path, which is arranged in the core engine casing and is defined by the compressor section, the combustion section, and the turbine section; and a third flow bypass airflow path, which is arranged between the fan bypass airflow path and the core flow path, which bypasses at least a portion of the core engine.

Description

Technical Field

[0001] The present subject matter generally relates to heat engines and turbines that include heat exchanger systems. Background Art

[0002] Heat engines such as gas and steam turbine engines may include heat exchangers for heat transfer of fluids throughout the engine. The cooled fluid is used for heat attenuation at various structures of the engine to increase component structural life, or to improve or change the aerodynamic or thermodynamic cycle of the engine.

[0003] However, heat exchanger systems within heat engines are generally limited in performance, thereby limiting the extent to which fluids can be cooled. Therefore, cooling fluids are limited in their ability to provide thermal attenuation to increase the life of component structures. In addition, due to pressure losses through the heat exchanger, known heat exchangers are generally limited in the extent to which cooling fluids can be provided to one or more components or systems. Therefore, a sufficiently cooled fluid may lack the pressure necessary to overcome the higher pressure sections of the heat engine (e.g., at the combustion section or expansion section). This limitation becomes more problematic when heat engines (such as turbines) generally increase or attempt to increase the temperature or pressure of the combustion gases at the combustion section and expansion section, thereby exposing structures within them and thermally close to higher temperatures (which can shorten the life of components or systems).

[0004]

[0006] Therefore, there is a need to provide heat engines and heat exchangers that provide improved heat transfer to a cooling fluid for heat decay at various components or systems of the heat engine. Summary of the invention

[0005] Aspects and advantages of the invention will be set forth in the following description, or may be obvious from the description, or may be learned through practice of the invention.

[0006] Aspects of the present disclosure relate to a heat engine comprising: a compressor that provides a compressed air flow from a core flow path of the heat engine; a cooled cooling air (CCA) heat exchanger system to which the compressed air flow is provided from the compressor; a coolant supply system that provides the coolant flow to the CCA heat exchanger so as to be in thermal communication with the compressed air flow at the CCA heat exchanger, wherein the coolant supply system and the CCA heat exchanger together define a CCA circuit through which the compressed air flows and is in thermal communication with the coolant; and a hot section disposed downstream of the compressor section along the core flow path through which combustion gases flow, wherein the hot section defines a secondary flow path through which the compressed air flow from the CCA heat exchanger is provided.

[0007] In one embodiment, the compressed air flow defines an inlet temperature and an inlet pressure from a core flow path at a compressor section. The compressed air flow defines an outlet temperature at a secondary flow path at a hot section that is between about 2% and about 50% less than the inlet temperature. The compressed air flow defines an outlet pressure at the secondary flow path that is greater than about 90% of the inlet pressure of the compressed air flow at the core flow path at the compressor section.

[0008] In various embodiments, the CCA heat exchanger includes one or more heat exchanger elements through which a coolant flows and is in thermal communication with compressed air from a compressor section. In one embodiment, the CCA heat exchanger further includes one or more valves disposed between the plurality of heat exchanger elements. The valve selectively bypasses at least a portion of the compressed air flow from the one or more heat exchanger elements. In another embodiment, the CCA heat exchanger further recombine one or more compressed air flows from the plurality of heat exchanger elements to produce a compressed air flow defining an outlet temperature and / or outlet pressure. In other various embodiments, the plurality of heat exchanger elements are arranged in parallel. In yet other various embodiments, the plurality of heat exchanger elements are arranged in a series flow arrangement.

[0009] In one embodiment, the coolant supply system defines one or more of a fuel system, a lubricant system, a hydraulic fluid system, a refrigerant system, a bypass air flow path, or a compressor bleed.

[0010] In another embodiment, the coolant is a liquid or gaseous fuel, a refrigerant, a supercritical gas, a liquid metal, an inert gas, a bypass air stream, compressed air, or a combination thereof.

[0011] Another aspect of the present disclosure relates to a heat engine, comprising: a core engine, the core engine including a compressor section configured to generate a compressed air flow and a hot section defining a secondary flow path; a cooling cooling air (CCA) heat exchanger system disposed in a series flow arrangement between the compressor section and the hot section, wherein the compressor section, the CCA heat exchanger system, and the secondary flow path of the hot section together define a CCA loop; a coolant supply system configured to provide a coolant flow to the CCA heat exchanger system; and a controller including a processor and a memory configured to store instructions that, when executed by the processor, cause the processor to perform operations. The operations include: flowing compressed air defining an inlet temperature and an inlet pressure from the compressor section through the CCA loop in thermal communication with coolant from the coolant supply system; and flowing compressed air from the CCA heat exchanger to the secondary flow path, the compressed air defining an outlet temperature at the hot section that is between about 2% and about 50% less than the inlet temperature, and also defining an outlet pressure at the secondary flow path that is about 90% or more of the inlet pressure.

[0012] In various embodiments, the operations further include: generating a compressed air flow at the compressor section at a high power state of the heat engine; and extracting at least a portion of the compressed air flow from the compressor section to the CCA loop. In one embodiment, the operations further include operating the CCA heat exchanger to generate a maximum temperature increase at the coolant defining one or more of bypass air, refrigerant, supercritical fluid, liquid metal, fuel, inert gas, or compressed air.

[0013] In various other embodiments, the operations further include: generating a compressed air flow at the compressor section at a low or medium power state of the heat engine; and extracting at least a portion of the compressed air flow from the compressor section to the CCA circuit. In one embodiment, the operations further include interrupting a coolant flow defining one or more bypass air flows when the heat engine defines a low or medium power state.

[0014] In yet other various embodiments, the operation further comprises adjusting a valve at the CCA heat exchanger to define different temperatures and different pressures of the compressed air stream. In one embodiment, the operation further comprises adjusting one or more of the inlet temperature and inlet pressure of the compressed air by adjusting the location in the compressor from which the compressed air from the core flow path is provided to the CCA heat exchanger. In another embodiment, one or more of the inlet temperature and inlet pressure of the compressed air is adjusted by mixing the compressed air stream from the core flow path.

[0015] In one embodiment, the operations further include determining a desired outlet temperature, outlet pressure, or both for the compressed air based at least on an operating state of the heat engine.

[0016] In another embodiment, operations further include adjusting one or more valves at the CCA heat exchanger to mix coolant at a first outlet temperature and / or a first outlet pressure with coolant at an inlet temperature and / or inlet pressure to produce coolant at a desired outlet pressure and temperature.

[0017] In various embodiments, operation also includes maintaining the temperature of the coolant within operating constraints relative to a desired outlet temperature and / or pressure of the coolant flow out of the CCA heat exchanger. In one embodiment, the operating constraints include one or more of a maximum fuel temperature at the combustion section, a maximum lubricant temperature, or minimizing bypass air flow.

[0018] These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims.The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the present invention and together with the description serve to explain the principles of the present invention.

[0019] Technical Solution 1. A gas turbine engine, comprising:

[0020] Fan assembly;

[0021] a core engine disposed downstream of the fan assembly and comprising a core engine casing, a compressor section downstream of the fan assembly, a combustion section downstream of the compressor section, and a turbine section downstream of the combustion section;

[0022] a fan bypass air flow path disposed downstream of the fan assembly and outside of the core engine casing;

[0023] a core flow path disposed within the core engine casing and defined by the compressor section, the combustion section, and the turbine section; and

[0024] a third flow bypass air flow path disposed between the fan bypass air flow path and the core flow path, which bypasses at least a portion of the core engine,

[0025] wherein the air flow from the fan assembly is divided into a first portion that enters the fan bypass airflow path and a second portion that enters the core engine casing,

[0026] wherein the second portion is divided within the core engine casing between the core flow path and the third flow bypass air flow path,

[0027] Wherein, the entirety of the airflow passing through the third flow bypass airflow passage merges with the airflow of the fan bypass airflow passage at an axial position axially before at least a portion of the turbine section.

[0028] Technical Solution 2. The gas turbine engine according to Technical Solution 1, wherein the third flow bypass airflow path is at least partially defined by the core engine casing from the compressor section to the fan bypass airflow path.

[0029] Technical Solution 3. The gas turbine engine according to Technical Solution 1, wherein the third flow bypass airflow passage selectively allows the flow of compressed air from the compressor section to mix with the air flow passing through the fan bypass airflow passage.

[0030] Technical Solution 4. A gas turbine engine according to Technical Solution 1, wherein the third flow bypass air flow path is at least partially defined by the core engine casing from the compressor section downstream of the low-pressure compressor of the compressor section and upstream of the high-pressure compressor of the compressor section to the fan bypass air flow path.

[0031] Technical Solution 5. A gas turbine engine according to Technical Solution 2, wherein the third flow bypass airflow path is configured to completely or partially shut off the flow of compressed air from the compressor section to prevent it from flowing out to the fan bypass airflow path based on the first operating state of the gas turbine engine.

[0032] Technical Solution 6. A gas turbine engine according to Technical Solution 5, wherein the first operating state of the gas turbine engine is a high power state, and wherein the flow of compressed air from the compressor section is completely or partially shut off to prevent it from flowing out to the fan bypass air flow path to increase the thrust output of the gas turbine engine.

[0033] Technical Solution 7. A gas turbine engine according to Technical Solution 2, wherein the third flow bypass airflow path is configured to open the flow of compressed air from the compressor section to flow out to the fan bypass airflow path based on a second operating state of the gas turbine engine.

[0034] Technical Solution 8. A gas turbine engine according to Technical Solution 7, wherein the second operating state of the gas turbine engine is a low or medium power state, and wherein opening the flow of compressed air from the compressor of the compressor section to flow out to the fan bypass air flow path reduces the fuel consumption of the gas turbine engine.

[0035] Technical Solution 9. The gas turbine engine according to Technical Solution 1 further comprises:

[0036] A cooled cooling air (CCA) heat exchanger system is provided wherein at least a first portion of the CCA heat exchanger system is disposed in the third stream bypass airflow path.

[0037] Technical Solution 10. The gas turbine engine according to Technical Solution 9, wherein at least a second portion of the CCA heat exchanger system is disposed in the fan bypass airflow path downstream of the third flow bypass airflow path.

[0038] Technical Solution 11. The gas turbine engine according to Technical Solution 10 further comprises:

[0039] a coolant supply system that provides a coolant flow to the CCA heat exchanger system,

[0040] Wherein, at least a first portion of the coolant supply system is disposed in the fan bypass air flow path upstream of a second portion of the CCA heat exchanger system.

[0041] Technical Solution 12. A gas turbine engine according to Technical Solution 11, wherein at least a second portion of the coolant supply system is disposed in the fan bypass airflow passage at an axial position where the third flow bypass airflow passage merges with the fan bypass airflow passage.

[0042] Technical Solution 13. A gas turbine engine according to Technical Solution 10, wherein the first portion of the CCA heat exchanger system is disposed in the third flow bypass airflow passage at an axial position where the third flow bypass airflow passage merges with the fan bypass airflow passage.

[0043] Technical Solution 14. A gas turbine engine according to Technical Solution 11, wherein at least a third portion of the CCA heat exchanger system is disposed at an inlet of the third flow bypass air flow path.

[0044] Technical Solution 15. The gas turbine engine according to Technical Solution 2, wherein the third flow bypass airflow passage is merged with the fan bypass airflow passage and has an exhaust portion outside the core engine.

[0045] Technical Solution 16. A gas turbine engine according to Technical Solution 15, wherein the third flow bypass airflow passage merges with the fan bypass airflow passage at an axial position behind the entirety of the compressor section.

[0046] Technical Solution 17. A gas turbine engine according to Technical Solution 16, wherein the third flow bypass airflow passage merges with the fan bypass airflow passage at an axial position before the entirety of the turbine section.

[0047] Technical Solution 18. The gas turbine engine according to Technical Solution 1 further comprises:

[0048] Cooled Cooling Air (CCA) heat exchanger system; and

[0049] a coolant supply system that provides a coolant flow to the CCA heat exchanger system,

[0050] wherein at least a portion of the CCA heat exchanger system is disposed at the inlet of the third flow bypass air flow path, and wherein at least a portion of the coolant supply system is disposed at the same axial position in the fan bypass air flow path as a portion of the CCA heat exchanger system is disposed at the inlet of the third flow bypass air flow path.

[0051] Technical Solution 19. The gas turbine engine according to Technical Solution 1, wherein the inlet portion of the third flow bypass air flow passage extends at an acute angle of less than 45° relative to the axial direction of the gas turbine engine.

[0052] Technical Solution 20. The gas turbine engine according to Technical Solution 1 further comprises:

[0053] Cooled Cooling Air (CCA) heat exchanger system; and

[0054] a secondary flow path in the combustion section through which a flow of compressed air from the CCA heat exchanger is provided,

[0055] wherein the flow of compressed air defines an inlet temperature and an inlet pressure from the core flow path at the compressor section,

[0056] wherein the flow of compressed air defines an exit temperature at the secondary flow path at the hot section that is between 20% and 50% less than the inlet temperature, and

[0057] wherein the flow of compressed air defines an outlet pressure at the secondary flow path that is greater than 90% of the inlet pressure of the flow of compressed air at the core flow path at the compressor section. BRIEF DESCRIPTION OF THE DRAWINGS

[0058] A complete and sufficient disclosure, including the best mode thereof, to one of ordinary skill in the art is set forth in the specification with reference to the accompanying drawings, in which:

[0059] Figure 1 is a schematic cross-sectional view of an exemplary embodiment of a heat engine including a cooled cooling air (CCA) heat exchanger system;

[0060] Figure 2-9 To draw Figure 1 An exemplary flow diagram of an embodiment of an engine and a heat exchanger in FIG. 1 ; and

[0061] Figure 10-11 A flow chart outlining exemplary steps for a method of operating an engine and heat exchanger system is provided.

[0062] Repeat use of reference characters in the present specification and drawings is intended to represent same or analogous features or elements of the invention.

[0063] Parts List

[0064] 10 Heat engine (or "engine")

[0065] 12 Axial centerline

[0066] 14 Fan assembly

[0067] 16 core engine

[0068] 18 Housing

[0069] 19 Core Flow Path

[0070] 20 Ring entrance

[0071] 21 Compressor Section

[0072] 21(a) Booster compressor

[0073] 22 (Booster or) Low Pressure (LP) Compressor

[0074] 24 High Pressure (HP) Compressor

[0075] 26 Combustion Section

[0076] 27 Secondary flow path (at / in the combustion zone)

[0077] 28 High Pressure (HP) Turbine

[0078] 30 Low Pressure (LP) Turbine

[0079] 31 Turbine section (or expansion section)

[0080] 32 Secondary flow path

[0081] 33 Hot Zone

[0082] 34 High pressure (HP) rotor shaft

[0083] 36 Low pressure (LP) rotor shaft

[0084] 37 Jet exhaust nozzle section

[0085] 38 Fan shaft

[0086] 40 Reduction gear

[0087] 42(s) fan blades

[0088] 44 Cabin

[0089] 46 Prop (or outlet guide vane)

[0090] 48 Fan bypass air flow path

[0091] 49 Third flow bypass air flow path

[0092] 74 A certain amount of air (arrow)

[0093] 76 Inlet associated with fan case or nacelle and / or fan assembly

[0094] 78 Part of air (arrow)

[0095] 79 Compressed air flow (arrow)

[0096] 80 Another part of the air (arrow)

[0097] 81 Arrows [plotting the increasing pressure and temperature of the (progressively) compressed air stream]

[0098] 82 Arrow [plots outlet temperature and pressure from compressor section (compressed air flow)]

[0099] 86 Combustion Gas

[0100] 91 Compressed air flow

[0101] 92 Another compressed air flow

[0102] 99 Portion of compressed air flow (81, 82) [provided from the core flow path at the compressor section]

[0103] 99(a) Portion of compressed air flow (99)

[0104] 99(b) Compressed air flow (99) [flowing through a plurality of heat exchanger elements]

[0105] 99(c) Arrow ["boost compressor 21(a) increases inlet pressure of compressed air 99 to CCA heat exchanger"]

[0106] 100 Cooled Cooling Air (CCA) Heat Exchanger System ("CCA Heat Exchanger")

[0107] 101 Compressed air [exhaust from CCA heat exchanger to hot section of engine]

[0108] 101(a) Compressed air flow [out of the series flow arrangement of the heat exchanger element The first one ]

[0109] 101(b) Compressed air flow [out of the series flow arrangement of the heat exchanger element] The second ]

[0110] 101(c) Compressed air flow [out of a series flow arrangement of heat exchanger elements] The third ]

[0111] 102 Compressed air flow (combustion section)

[0112] 103 Compressed air flow [may define the inlet into the secondary flow path at the blades, guide vanes, frame or casing of the high pressure turbine]

[0113] 104 Compressed air flow [may define the inlet into the secondary flow path at the blades, guide vanes, frame or casing of the low pressure turbine or exhaust section, or between the high pressure turbine and the low pressure turbine (e.g., turbine mid-frame or inter-turbine frame)]

[0114] 105 CCA loop

[0115] 109 Coolant

[0116] 109(a) [First outlet temperature and / or first outlet pressure] coolant

[0117] 109(b) Bypass flow [at least a portion of coolant flow 109(a)]

[0118] 109(c) Outlet flow of coolant [defined as being substantially higher in temperature than the inlet flow of coolant to the first heat exchanger element]

[0119] 109(d) [Inlet temperature and / or inlet pressure] of coolant

[0120] 110 Coolant supply system

[0121] 110(a) Second coolant supply system

[0122] 111 Coolant flow from a CCA heat exchanger or its heat exchanger elements

[0123] 111(a) Coolant [at expected outlet pressure and temperature]

[0124] 200 Heat exchanger elements

[0125] 200(a) First heat exchanger element

[0126] 200(b) Second heat exchanger element

[0127] 210 valve (or one or more valves)

[0128] 211 Controller

[0129] 212 Processor

[0130] 214 Associated Memory

[0131] 216 Control Logic

[0132] 220 Mixer

[0133] 230 Communication interface module

[0134] 1000 Method for operating a heat exchanger system of a heat engine

[0135] 1010 The compressed air having a defined inlet temperature and inlet pressure is flowed from the core flow path to the CCA heat exchanger to be in thermal communication with the coolant from the coolant supply system.

[0136] 1020 Flowing compressed air from the CCA heat exchanger to the hot section (e.g., at the secondary flow path), wherein the compressed air defines an outlet temperature between about 2% and about 50% (inclusive) less than the inlet temperature of the compressed air, and an outlet pressure at the hot section (e.g., at the secondary flow path) of about 90% or more of the inlet pressure of the compressed air.

[0137] 1022 Generate a compressed air flow defined in a high power state (e.g., takeoff power, or between 90% and 105% (inclusive) of the maximum speed of one or more shafts of the engine)

[0138] 1023 generating a compressed air flow at the compressor section at a low or medium power state (e.g., ignition, ground idle, flight idle, cruise or approach state, or between 20% and up to 90% of the maximum speed of one or more rotating shafts of the engine)

[0139] 1024 extracting at least a portion of the compressed air flow from the compressor section to the CCA circuit

[0140] 1025 Interrupt coolant flow defining one or more bypass air flows while the engine defines one or more low or medium power states

[0141] 1026 Operating the CCA heat exchanger to generate a maximum temperature rise at the coolant defining the fuel [Generating the compressed air flow at the high power state may also include operating the CCA heat exchanger 100 to generate a maximum temperature rise at the coolant 109 defining one or more of the bypass air 78, 79, the refrigerant, the supercritical fluid, the liquid metal, the fuel, the inert gas, or the compressed air, or a combination thereof.]

[0142] 1030 Adjust the valve at the CCA heat exchanger to define different temperatures and different pressures of the compressed air flow.

[0143] 1040 Adjusting one or more of the inlet temperature and the inlet pressure of the compressed air by adjusting the location in the compressor section from which the compressed air from the core flow path is provided to the CCA heat exchanger

[0144] 1050 Determine a desired outlet temperature, outlet pressure, or both of the compressed air based at least on the operating state of the engine

[0145] 1060 Adjust one or more valves at the CCA heat exchanger to mix the coolant at the first outlet temperature and / or the first outlet pressure with the coolant at the inlet temperature and / or the inlet pressure to produce the coolant at the desired outlet pressure and temperature.

[0146] 1070 Maintain the temperature of the coolant within operating constraints relative to a desired outlet temperature and / or pressure of the coolant flow from the CCA heat exchanger. DETAILED DESCRIPTION

[0147] Reference will now be made in detail to embodiments of the present invention, one or more examples of which are shown in the accompanying drawings. Each example is provided by way of illustrating the present invention rather than limiting the present invention. In fact, it will be apparent to those skilled in the art that various modifications and variations may be made in the present invention without departing from the scope or spirit of the present invention. For example, a feature shown or described as a part of an embodiment may be used together with another embodiment to produce yet another embodiment. Therefore, it is intended that the present invention covers such modifications and variations within the scope of the appended claims and their equivalents.

[0148] As used herein, the terms “first,” “second,” and “third” may be used interchangeably to distinguish one component from another, and are not intended to indicate the position or importance of the independent components.

[0149] The terms "upstream" and "downstream" refer to relative directions with respect to the flow of a fluid in a fluid pathway. For example, "upstream" refers to the direction from which the fluid is flowing, and "downstream" indicates the direction to which the fluid is flowing.

[0150] The approximation cited herein may include a margin based on one or more measuring devices as used in the art, such as, but not limited to, a percentage of the full-scale measurement range of the measuring device or sensor. Alternatively, the approximation cited herein may include a margin of 10% of the upper limit value greater than the upper limit value or 10% of the lower limit value less than the lower limit value.

[0151] Embodiments of heat engines and methods of operation including cooling cooling air (CCA) heat exchanger systems are generally provided. The structures and methods shown and described herein can provide improved heat transfer to the cooling fluid for thermal attenuation at various components or systems of the heat engine. The CCA heat exchanger system and method provided herein provide a desired amount of heat transfer from compressed air, such as between about 2% and about 50% less than the inlet temperature, while providing a pressure drop of about 10% or less of the inlet pressure of the compressed air for cooling the compressed air. Further, the CCA heat exchanger system and method generally provided herein maintain the coolant within a desired temperature range, such as below the maximum coolant temperature based on operating constraints. Therefore, the cooling fluid of the cooling of the compressed air is limited to provide a desired outlet temperature and outlet pressure so that cooling is provided to one or more components in the secondary flow path of the hot section of the engine (e.g., blades, guide vanes, casings, shrouds in the combustion section 26, turbine or expansion section 31 or exhaust section 37 of the heat engine 10 described below).

[0152] Referring now to the accompanying drawings, Figure 1 1 is a schematic partial cross-sectional side view of an exemplary heat engine 10 (referred to herein as “engine 10”) as may be incorporated with various embodiments of the present invention. Although engine 10 is further described herein as a turbofan engine, engine 10 may generally define a steam turbine engine or turbomachine, including turbojet, turbopropeller, or turboshaft gas turbine engine configurations. Figure 1 As shown in FIG. 1 , the engine 10 has a longitudinal or axial center axis 12 extending therethrough for reference purposes. Generally, the engine 10 may include a fan assembly 14 and a core engine 16 disposed downstream of the fan assembly 14 .

[0153] The core engine 16 may generally include a substantially tubular casing 18 defining an annular inlet 20 defining a core flow path 19 through the core engine 16. The casing 18 encloses or at least partially forms in series flow relationship: a compressor section 21 such as having a supercharger or low pressure (LP) compressor 22 and a high pressure (HP) compressor 24; a combustion section 26; and an expansion section or turbine section 31 such as including a high pressure (HP) turbine 28 and a low pressure (LP) turbine 30. The turbine or expansion section 31 also includes a jet exhaust nozzle section 37 through which the combustion gases 86 flow from the core engine 16. In various embodiments, the jet exhaust nozzle section 37 may further define an afterburner. The core engine 16 further defines a hot section 33, which includes the combustion section 26, the turbine or expansion section 31, and the jet exhaust nozzle section 37, through which the combustion gases 86 are formed and flow through them. A high pressure (HP) rotor shaft 34 drivingly connects the HP turbine 28 to the HP compressor 24. A low pressure (LP) rotor shaft 36 drivingly connects the LP turbine 30 to the LP compressor 22. The LP rotor shaft 36 may also be connected to a fan shaft 38 of the fan assembly 14. In certain embodiments, as shown in FIG. Figure 1 As shown in FIG. , the LP rotor shaft 36 may be connected to the fan shaft 38 via a reduction gear 40 (eg, in an indirect drive or gear drive configuration).

[0154] like Figure 1 , the fan assembly 14 includes a plurality of fan blades 42 coupled to the fan shaft 38 and extending radially outward from the fan shaft 38. An annular fan case or nacelle 44 circumferentially surrounds at least a portion of the fan assembly 14 and / or the core engine 16. Those of ordinary skill in the art will appreciate that the nacelle 44 may be configured to be supported relative to the core engine 16 by a plurality of circumferentially spaced outlet guide vanes or struts 46. In addition, at least a portion of the nacelle 44 may extend on the exterior of the outer casing 18 of the core engine 16 so as to define a fan bypass airflow path 48 therebetween.

[0155] During operation of the engine 10, a quantity of air, as schematically indicated by arrows 74, enters the engine 10 through the fan case or nacelle 44 and / or associated inlet 76 of the fan assembly 14. As the air 74 passes through the fan blades 42, a portion of the air, as schematically indicated by arrows 78, is directed or routed into the bypass airflow passage 48, while another portion of the air, as schematically indicated by arrows 80, is directed or routed into the core flow path 19 of the core engine 16 at the LP compressor 22. As schematically shown by arrows 81, which depict the increased pressure and temperature of the compressed air flow, and arrows 82, which depict the outlet temperature and pressure from the compressor section 21 (e.g., defining the inlet temperature and pressure of the combustion section 26), the air 80 is progressively compressed as it flows through the LP compressor 22 and the HP compressor 24 through the core flow path 19 toward the combustion section 26. The now compressed air 82 flows into the combustion section 26 to mix with the liquid or gaseous fuel and combust to produce combustion gases 86. Combustion gases 86 generated in combustion section 26 flow downstream through core flow path 19 into HP turbine 28, thereby causing HP rotor shaft 34 to rotate, thereby supporting operation of HP compressor 24. Combustion gases 86 are then directed through LP turbine 30 through flow path 19, thereby causing LP rotor shaft 36 to rotate, thereby supporting operation of LP compressor 22 and / or rotation of fan shaft 38 and fan blades 42. Combustion gases 86 are then exhausted through jet exhaust nozzle section 37 of core engine 16 to provide propulsive thrust.

[0156] In general Figure 1 In the embodiment provided in FIG. 1 , the engine 10 further defines a third flow bypass airflow path 49. The third flow bypass airflow path 49 is at least partially defined through the casing 18 from the compressor of the compressor section 21 (e.g., the LP compressor 22) to the fan bypass airflow path 48. The third flow bypass airflow path 49 selectively allows a flow (schematically indicated by arrows 79) of compressed air 80, 81 from the compressor of the compressor section 21 (e.g., from the LP compressor 22) to mix with a portion of the air 78 in the fan bypass airflow path 48. Based on the operating state of the engine 10 (e.g., a high power state), the engine 10 allows the third flow bypass airflow path 49 to completely or substantially close the flow 79 of compressed air from flowing out to the fan bypass airflow path 48 in order to increase the thrust output of the engine 10. Based on the operating state of engine 10 (eg, low or medium power state), engine 10 also allows third flow bypass airflow passage 49 to at least partially open flow 79 of compressed air to flow out to fan bypass airflow passage 48 to reduce fuel consumption.

[0157] It should be recognized that although Figure 1The exemplary embodiment of the engine 10 generally provided in FIG. 1 is presented as a three-flow turbofan configuration, but the engine 10 may define a two-flow heat engine configuration (e.g., fan bypass airflow path 48 and core flow path 19) or a single-flow heat engine configuration (e.g., core path 19). It should also be appreciated that although Figure 1 The exemplary embodiment of the engine 10 generally provided in FIG. 1 presents a two-shaft turbofan configuration, but the engine 10 may define a third or more spool configuration, wherein the LP compressor 22 defines an intermediate pressure (IP) compressor coupled to an IP shaft and an IP turbine, each of which is disposed in series flow relationship between a corresponding fan assembly 14, an HP compressor 24, an HP turbine 28, and an LP turbine 30. Still further, the three-shaft configuration may also couple the fan assembly 14 to an LP turbine 30 that is mechanically independent relative to the LP / IP compressor 22 and the IP turbine. Alternatively stated, the engine 10 may define three mechanically independent spools that include a corresponding combination of a fan assembly and an LP turbine, an IP compressor and an IP turbine, and an HP compressor and an HP turbine.

[0158] Still refer to Figure 1 , and further together with Figure 2 Another exemplary schematic diagram of engine 10 is provided in FIG. 1 , which also includes a cooled cooling air (CCA) heat exchanger system 100 (hereinafter “CCA heat exchanger 100 ”). Figure 2 The diagram provided in the figure generally depicts the Figure 1 An embodiment of fluid flow for an embodiment of engine 10 is generally provided and described. Figure 1 , the CCA heat exchanger 100 may be defined in one or more of the fan bypass airflow path 48, the tertiary flow bypass airflow path 49, the casing 18, or the combustion section 26. In various embodiments, the CCA heat exchanger 100 is defined in one or more of the outlet guide vanes or struts 46 of the fan assembly 14. For example, the CCA heat exchanger 100 may be disposed in the struts 46 or casing 18 and be in thermal communication with one or more of the bypass airflow paths 48, 49. As another example, the CCA heat exchanger 100 may be coupled to the fan case or nacelle 44, the casing 18 of the core engine 16, or both, or be disposed in the fan case or nacelle 44, the casing 18 of the core engine 16, or both. As yet another example, the CCA heat exchanger 100 may be disposed in the combustion section 26, such as in contact with the core flow path 19 or the secondary flow path 27 ( Figure 2 ) are in thermal connectivity.

[0159] Reference Figure 2, the CCA heat exchanger 100 receives a portion of the compressed air flow 81, 82 provided from the core flow path 19 at the compressor section 21, which is schematically shown by the arrow 99 entering the CCA heat exchanger 100. In various embodiments, the compressed air 99 may be a portion of the compressed air 81 in the stage (mid-stage) within the compressor section 21. For example, the compressed air 81 is defined between the inlet and outlet of the compressor section 21 so as to define a temperature and / or pressure of the compressed air 81 and subsequently the compressed air 99, which is less than the maximum temperature and / or pressure of the compressed air 82 entering the combustion section 26. Alternatively, the compressed air 99 entering the CCA heat exchanger 100 may be a portion of the compressed air 82 entering the combustion section 26 (e.g., compressor discharge air, station 3.0) so as to define a temperature / pressure greater than the compressed air 81 in the stage from the compressor section 21. In other various examples, as further described below, the engine 10 may adjust or change the location of the compressed air 81, 82 from which the flow of compressed air 99 is extracted to enter the CCA heat exchanger 100. The compressed air 99 entering the CCA heat exchanger 100 defines an inlet temperature and an inlet pressure. The inlet temperature and inlet pressure of the compressed air 99 entering the CCA heat exchanger 100 are substantially equal to the temperature and pressure at the core flow path 19 of the compressor section 21 from which the compressed air 99 is extracted from the compressed air flow 81, 82.

[0160] It should be appreciated that as a portion of the compressed air 99 flows out of the core flow path 19 to the CCA heat exchanger 100, a loss in temperature and pressure generally follows based at least on the length, area or volume, or leakage along the flow path between the compressor section 21 and the CCA heat exchanger 100. Therefore, references to inlet temperature and inlet pressure described herein may generally represent the highest temperature and highest pressure of the compressed air 99 drawn from the core path 19. Alternatively, the inlet temperature and inlet pressure of the compressed air 99 may be generally considered to be equal to the temperature and pressure of the compressed air 81, 82 at the station or stage along the compressor section 21 from which the compressed air 99 is drawn to the CCA heat exchanger 100.

[0161] The engine 10 also includes a coolant supply system 110 that provides a coolant flow 109 to the CCA heat exchanger 100. The coolant 109 is provided in thermal communication with the compressed air 99 at the CCA heat exchanger 100. The coolant 109 entering the CCA heat exchanger 100 extracts or transfers thermal energy from the compressed air 99 to cool it to an outlet temperature defined at the compressed air 101 that is discharged from the CCA heat exchanger 100 to the hot section 33 of the engine 10.

[0162] In various embodiments, the outlet temperature of the compressed air 101 discharged from the CCA heat exchanger 100 to the hot section 33 is between about 90% and about 50% of the inlet temperature of the compressed air 99 upstream of the CCA heat exchanger 100. In one embodiment, the outlet temperature of the compressed air 101 at the hot section 33 is between about 80% and about 50% (inclusive) of the inlet temperature of the compressed air 99. In other various embodiments, the compressed air 101 more specifically defines the outlet temperature at the secondary flow path 27 at the combustion section 26, as schematically shown by the compressed air flow 102 at the combustion section 26. In yet another embodiment, as schematically shown by the compressed air flows 103, 104, the compressed air 101 more specifically defines the expansion section 31 (including the exhaust section 37 ( Figure 1 32 at the outlet temperature of the secondary flow path 32 at the expansion section 31). Further, the compressed air flow 103 defines a higher pressure upstream of the compressed air 104 relative to the core flow path 19 at the expansion section 31. For example, referring to Figure 1 and Figure 2 , the compressed air 103 may define an inlet of the secondary flow path 32 entering at a blade, vane, frame, or casing of the high pressure turbine 28. As another example, the compressed air 104 may define an inlet of the secondary flow path 32 entering at a blade, vane, frame, or casing of the low pressure turbine 30 or the exhaust section 37, or between the high pressure turbine 28 and the low pressure turbine 30 (e.g., a turbine mid-frame or an inter-turbine frame).

[0163] The CCA heat exchanger 100 also includes a CCA conduit 105 that defines a walled conduit or manifold that provides compressed air 99, 101 from the core flow path 19 at the compressor section 21, the combustion section 26, or both to the CCA heat exchanger 100. The CCA loop 105 further defines a walled conduit or manifold from the CCA heat exchanger 100 to the hot section 33 of the engine 10. In various embodiments, the CCA conduit 105 is more specifically defined to the secondary flow path 27 at the combustion section 26, the secondary flow path 32 at the expansion section 31, or both. Thus, in one embodiment, the CCA loop 105 provides compressed air 99 to the CCA heat exchanger 100 from a portion of the mid-stage flow of the compressed air 81 at the compressor section 21, generally schematically shown at 91. In another embodiment, CCA circuit 105 provides compressed air 99 to CCA heat exchanger 100 , schematically shown at 92 , from a portion of compressed air flow 82 that is compressor discharge air downstream of compressor section 21 (eg, at combustion section 26 upstream of combustors).

[0164] The CCA heat exchanger 100 including the CCA loop 105 defines walled conduits, manifolds, and openings (e.g., cross-sectional areas) to minimize pressure losses through increased diameters or cross-sectional areas. The passages within the CCA heat exchanger 100 are sized to minimize pressure losses while further defining the flow rate of the compressed air 99, 101 therethrough to provide a desired change in temperature from an inlet temperature at the compressed air 99 to an outlet temperature at the compressed air 101.

[0165] The CCA heat exchanger 100 defines a pressure loss or pressure drop which is defined by:

[0166]

[0167] The pressure loss or pressure drop is defined by at least the difference between a first pressure P1 upstream of CCA heat exchanger 100 (eg, at compressed air 99 ) and a second pressure P2 downstream of CCA heat exchanger 100 (eg, at compressed air 101 ), both divided by the first pressure P1 .

[0168] In various embodiments, the CCA heat exchanger 100 defines a pressure loss of approximately 10% or less between the upstream inlet pressure of the compressed air 99 at the compressor section 21 and the downstream outlet pressure of the compressed air 101 at the hot section 33. In one embodiment, the CCA heat exchanger 100 provides the outflowing compressed air 101 to the hot section 33 (e.g., at the secondary flow paths 27, 32 or into the core flow path 19) that defines an outlet pressure or P2 of approximately 90% or greater of the inlet pressure or P1 of the inlet compressed air 99 into the CCA heat exchanger 100. In another embodiment, the outlet pressure or P2 at the secondary flow paths 27, 32 is approximately 105% or greater of the pressure of the combustion gases 86 at the core flow path 19 at the expansion section 31. Thus, the CCA heat exchanger 100 provides a compressed air flow 101 at a pressure sufficient to ensure the desired flow direction (i.e., from the secondary flow paths 27, 32 to the core flow path 19 at the hot section 33).

[0169] In various embodiments, the coolant 109, 111 defines a liquid or gaseous fuel, compressed air, a refrigerant, a liquid metal, an inert gas, a supercritical fluid, compressed air, or a combination thereof. Various embodiments of the coolant 109, 111 defining a supercritical fluid may include, but are not limited to, carbon dioxide, water, methane, ethane, propane, ethylene, propylene, methanol, ethanol, acetone, or nitrous oxide, or a combination thereof.

[0170] In other various embodiments, the coolant 109, 111 defining the refrigerant may include, but is not limited to, halogenated alkanes, perchloroolefins, perchlorocarbons, perfluoroolefins, perfluorocarbons, hydrogenated olefins, hydrocarbons, hydrochloroolefins, hydrochlorocarbons, hydrofluoroolefins, hydrofluorocarbons, hydrochloroolefins, hydrochlorofluorocarbons, chlorofluoroolefins, or chlorofluorocarbon-based refrigerants, or combinations thereof.

[0171] Various other embodiments of the coolant 109, 111 defining the refrigerant may include methylamine, ethylamine, hydrogen, helium, ammonia, water, neon, nitrogen, air, oxygen, argon, sulfur dioxide, carbon dioxide, nitrous oxide, or krypton, or combinations thereof.

[0172] In yet other various embodiments, the fuel comprising the coolant 109, 111 defining a liquid or gaseous fuel may include, but is not limited to, gasoline or petroleum, propane, ethane, hydrogen, diesel, kerosene, or one or more jet fuel formulations (e.g., Jet A, JP1, etc.), coke oven gas, natural gas or syngas, or combinations thereof.

[0173] In various other embodiments, the coolant 109, 111 defining the air may include, for example, Figure 1 Bypass air flows 78 , 79 from the fan assembly 14 or compressor section 21 around the combustion section 26 are depicted, as well as flow through the fan bypass airflow path 48 and / or the third flow bypass airflow path 49 .

[0174] Now refer to Figure 3-6 , provides a flow diagram that plots the Figure 1-2 At least a portion of engine 10 is generally shown and described. Figure 3-6 The embodiments provided in the Figure 1-2 Components or details within the CCA heat exchanger 100 are generally provided in FIG.

[0175] Now refer to Figure 3 , the CCA heat exchanger 100 may include one or more heat exchanger elements 200 through which the coolant flow 109 enters and is in thermal communication with the compressed air flow 99. The CCA heat exchanger 100 may include a plurality of heat exchanger elements 200 that are arranged in a substantially series flow arrangement with each other relative to the compressed air flow 99 from the compressor section 21 to the hot section 33. The CCA heat exchanger 100 may also include one or more valves 210 disposed between the plurality of heat exchanger elements 200. In various embodiments, the valve 210 defines a bypass valve so as to bypass at least a portion of the compressed air flow 99 from one or more other heat exchanger elements 200 to be discharged to or out of the hot section 33 as one or more compressed air flows 102, 103, 104 defining outlet temperatures and outlet pressures that are different from each other.

[0176] For example, as the compressed air stream 99 enters and exits each heat exchanger element 200, the streams define different outlet temperatures and different outlet pressures relative to each other, as schematically shown by arrows 101(a), 101(b), 101(c). For example, the compressed air stream 101(a) that flows out of the first of the series arrangement of heat exchanger elements 200 generally defines an outlet temperature and outlet pressure within the ranges described above. A portion of the compressed air stream 101(a) that flows out of the first heat exchanger element 200 is directed to the hot section 33 via valve 210. For example, valve 210 diverts a portion of the compressed air 101(a) schematically shown by arrow 104 to the hot section 33. When the first compressed air stream 101(a) generally defines a lower temperature change and pressure drop than the subsequent compressed air series streams 101(b), 101(c), a portion of the compressed air stream 101(a) may be directed to the hot section 33 as compressed air stream 104.

[0177] As another example, the compressed air stream 101(b) exiting the second one of the series flow arrangements of the heat exchanger elements 200 is substantially limited to an outlet temperature and outlet pressure within the above ranges and less than a portion of the oxidant stream 101(a). The second one of the valves 210 further directs at least a portion of the oxidant stream 101(b) to the hot section 33, such as via the compressed air stream 102.

[0178] As yet another example, the compressed air stream 101(c) exiting the third of the series flow arrangements of the heat exchanger elements 200 is substantially limited to an outlet temperature and outlet pressure within the above ranges and less than a portion of the oxidant stream 101(b). The third of the valves 210 further directs at least a portion of the oxidant stream 101(c) to the hot section 33, such as via the compressed air stream 103.

[0179] Now refer to Figure 4 In the exemplary embodiment generally provided in FIG. 1 , valve 210 defines a bypass valve to bypass at least a portion of a compressed air flow 99, schematically indicated by arrow 99(a), from one or more other heat exchanger elements 200. The bypassed compressed air flow 99(a), defining various outlet temperatures and outlet pressures, is then recombined with the compressed air flow 99 flowing through the plurality of heat exchanger elements, schematically indicated by arrow 99(b), to output a compressed air flow 101 defining outlet temperatures and outlet pressures as defined above from the CCA heat exchanger 100 to the hot section 33.

[0180] In one embodiment, the CCA heat exchanger 100 further includes a mixer 220 to which the individual compressed air streams 99 (a), 99 (b) are provided and recombined to produce the output compressed air 101. The mixer 220 combines one or more compressed air streams 99 from the heat exchanger element 200 to standardize or average the pressure and / or temperature of the one or more compressed air streams 99 to produce or flow out the output compressed air 101. For example, referring to Figure 4 , the mixer 220 receives a bypass stream of compressed air 99(a), and another compressed air stream processed by the additional heat exchanger element 200, schematically shown by arrow 99(b). The bypass compressed air stream 99(a) may generally define a different temperature and / or pressure than the compressed air stream 99(b) processed by the additional heat exchanger element 200. The mixer 220 receives and mixes the compressed air streams 99(a), 99(b), and causes an outlet compressed air stream 101 that defines a desired outlet temperature and outlet pressure to flow out. In yet other embodiments, the mixer 220 may also (or alternatively) receive and mix a portion of the compressed air stream 82 flowing out of the compressor section 21 with one or more compressed air streams 99(a), 99(b), 101 processed by one or more heat exchanger elements 200.

[0181] In general, such as Figure 1-4 In various embodiments provided, the coolant supply system 110 defines a fluid system that provides a coolant flow 109 to the CCA heat exchanger 100 (or more specifically, one or more heat exchanger elements 200 at the CCA heat exchanger 100). The coolant supply system 110 may define one or more of a fluid system, such as a fuel system, a lubricant system, a hydraulic fluid system, a refrigerant system, one or more compressor bleed devices, or another system that provides a coolant flow 109, 111. In other embodiments, the coolant supply system 110 extracts or provides an air flow as the coolant 109, 111 from one or more of the bypass air flow passages 48, 49. In still other embodiments, the coolant supply system 110 extracts or provides an air flow as the coolant 109, 111 from one or more compressor bleed devices or stages along the compressor section 21. In other various embodiments, a plurality of coolant supply systems 110 each define one or more embodiments of a fluid system as generally described above.

[0182] Refer generally to Figure 3-4 In the provided example, each coolant supply system 110 provides a coolant flow 109 to each heat exchanger element 200. Thus, each combination of a coolant supply system 110 and a heat exchanger element 200 may define a different heat transfer rate, temperature change between the compressed air 99 and the coolant 109, and a different pressure drop.

[0183] Now refer to Figure 5 , provides information including generally about Figure 1-4 Another exemplary flow diagram of engine 10 is shown and described with a CCA heat exchanger 100. However, in Figure 5 In the embodiment, a plurality of heat exchanger elements 200 are arranged in a parallel flow arrangement relative to each other between the compressor section 21 and the expansion section 31. Figure 4 As described, the parallel arrangement of heat exchanger elements 200 is selectively operable to produce a desired change in temperature and pressure drop between the inlet temperature / pressure of compressed air 99 and the outlet temperature / pressure of compressed air 101. Further, the parallel arrangement of heat exchanger elements 200 reduces the inlet compressed air flow 99 so as to reduce the associated pressure losses while increasing heat transfer to the coolants 109, 111.

[0184] Reference Figure 3-5 , the arrangement of the heat exchanger elements 200 may also allow for maintaining or adjusting the temperature / pressure of the individual coolant flows 109, 111 at the individual heat exchanger elements 200. For example, the individual coolant flows 109 from the individual coolant supply systems 110 may each define an operational constraint relative to a desired outlet or discharge temperature / pressure of the coolant flow 111 flowing out of the CCA heat exchanger 100 or its individual heat exchanger elements 200. Such operational constraints may include a maximum fuel temperature at the combustor fuel manifold at the combustion section 26 (e.g., based on health, safety, operability, or fuel usability parameters); a maximum coolant temperature where the outflow flow of the coolant 111 is further used for one or more other systems (e.g., an environmental control system (ECS), one or more computers, electronic equipment, motors, generators / motors, bearing assemblies, hydraulic systems, clearance control systems, etc.); a maximum lubricant temperature (e.g., based on the vibration response of the bearing assembly or the engine 10); or minimizing adverse effects on the aerodynamic cycle of the engine 10 by minimizing the use or amount of bypass air flows 78, 79.

[0185] Now refer to Figure 6 , provides information including generally about Figure 1-5 Yet another exemplary schematic flow chart of an engine 10 with a CCA heat exchanger 100 is shown and described. Figure 5In the embodiment generally provided in , a coolant supply system 110 provides a coolant stream 109 to a plurality of heat exchanger elements 200 in series flow. More specifically, a first heat exchanger element 200 (a) receives a compressed air stream 99 defining an inlet temperature and an inlet pressure from the compressor section 21. The coolant 109 at the first heat exchanger element 200 removes heat energy from the compressed air 99 to produce a compressed air stream 101 of a defined outlet temperature and an outlet pressure flowing out to the expansion section 31. A second coolant supply system 110 (a) provides another coolant stream 109 (a) to a second heat exchanger element 200 (b). The second heat exchanger element 200 (b) receives an outlet coolant stream 109 (c) from the first heat exchanger element 200 (a) defining a substantially higher temperature than the inlet coolant stream 109 to the first heat exchanger element 200 (a). The coolant stream 109 (c) enters the second heat exchanger element 200 (b) and is in thermal communication with the coolant stream 109 (a). In various embodiments, at least a portion of the coolant stream 109 (a) may bypass the second heat exchanger element 200 (b) via valve 210, as depicted by arrow 109 (b). In other various embodiments, the bypass stream 109 (b) may be mixed with the outlet stream of the second heat exchanger element 200 (b) schematically shown at 109 (d) at the mixer 220. The mixer 220 produces a temperature / pressure standardized coolant stream 111 (a) flowing to the combustion section 26. In various embodiments, the coolant stream 111 (a) may define compressed air that provides cooling to the combustion section 26. In other embodiments, the coolant 111 (a) defines the fuel used to produce the combustion gases 86.

[0186] Generally speaking Figure 3-6 In the embodiments provided in the drawings, the coolant supply system 110 may define a partially closed loop or a substantially closed loop. For example, the coolant 109 may flow in thermal communication through one or more heat exchanger elements 200 and return (as coolant 111) to the coolant supply system 110. As another example, the coolant 109, 111 may also flow in thermal communication with one or more other systems (generally, bearing assemblies, ECS, gear assemblies, dampers, motors, electronic equipment, computers, or hydraulic systems or heat sinks) before returning to the coolant supply system 110.

[0187] Now refer to Figure 7-8 , provides information including generally about Figure 1-5 Another exemplary flow diagram of engine 10 is shown and described with reference to CCA heat exchanger 100. Figure 7-8, the engine 10 may also include a booster compressor 21(a) arranged in series flow between the compressor section 21 and the CCA heat exchanger 100. The booster compressor 21(a) increases the inlet pressure of the compressed air 99 into the CCA heat exchanger 100, as schematically shown by arrow 99(c). Thus, the CCA heat exchanger 100 may define a higher pressure loss relative to the increased pressure of the compressed air 99(c) from the booster compressor 21(a) in order to define the compressed air 101 at an outlet temperature and outlet pressure (e.g., greater than the pressure of the combustion gases 86) as described above.

[0188] Now refer to Fig. 9 , provides information including generally about Figure 1-7 Another exemplary flow diagram of an engine 10 is shown and described with a CCA heat exchanger 100. In the embodiment generally provided, coolant 109, 111 flows through a plurality of CCA heat exchanger systems 100 and a coolant supply system 110 in a substantially closed loop arrangement. The plurality of CCA heat exchanger systems 100 and the coolant supply system 110 are arranged in a series flow arrangement with respect to the coolant flow 109, 111 therethrough.

[0189] Still refer to Fig. 9 , a compressed air stream 91 from the mid-stage flow of compressed air 81 in the compressor section 21 is extracted and provided to the CCA heat exchanger 100. The compressed air stream 91 is provided in thermal communication with the outlet coolant stream 111 from the upstream CCA heat exchanger 100. The resulting cooled compressed air stream 104 is provided to the secondary flow path 32 at the expansion section 31. More specifically, the compressed air stream 104 is provided relatively downstream in the secondary flow path 32, such as to the LP turbine 30 (opposite to the HP turbine 28). Figure 1 ).

[0190] Another compressed air stream 92 from downstream of the compressor section 21 is extracted and provided to another CCA heat exchanger 100. A coolant stream 109 is provided to the CCA heat exchanger 100 in thermal communication with the compressed air stream 92 to produce compressed air streams 102, 103 defining a desired outlet temperature and outlet pressure. As previously described, the compressed air stream 92 defines a greater temperature and pressure than the compressed air stream 91 extracted further upstream in the compression section 21. Therefore, the compressed air 92 is provided to the more upstream CCA heat exchanger 100, so that the coolant 109 defines a cooler temperature or generally greater heat transfer potential relative to the coolant 111 flowing out of the CCA heat exchanger 100 and provided to the other CCA heat exchanger 100.

[0191] Alternatively, compressed air flow 91 defines a lesser temperature and pressure than compressed air flow 92 extracted further downstream of compressor section 21. Thus, compressed air 91 is provided to the more downstream CCA heat exchanger 100 such that coolant 111 defines a hotter temperature or substantially less heat transfer potential relative to coolant 109 provided to the upstream CCA heat exchanger 100.

[0192] Now refer to Figure 10-11 , generally provides a flow chart outlining exemplary steps of a method for operating a heat exchanger system for a heat engine (hereinafter "method 1000"). Method 1000 may be described in connection with Figure 1-9 The various embodiments of the engine 10 generally shown and described are used or implemented. Figure 1-9 The embodiment of the engine 10 and CCA heat exchanger 100 shown and described describes the method 1000, but it should be appreciated that the method 1000 may be further used or implemented in other engine and heat exchanger systems. Further, although the method 1000 is presented below in a particular order, it should be appreciated that the method 1000 may be reordered, rearranged, or steps may be removed, omitted, or rearranged without departing from the scope of the present disclosure.

[0193] Still further, the method 1000 may be performed via the engine 10 ( Figure 1 ) is executed by a controller 211 at ) to selectively flow, adjust, regulate or change one or more compressed air flows 91, 92, 99, 101, 102, 103, 104 or coolant flows 109, 111, valve 210 or coolant supply system 110. Various embodiments of the controller 211 are configured to store and execute instructions to perform operations, such as one or more steps of an embodiment of the method 1000 provided herein. The controller 211 is further configured to transmit, command, receive or store instructions or data for operating the engine 10 including the CCA heat exchanger 100. In general, the controller 211 may correspond to any suitable processor-based device, including one or more computing devices. For example, Figure 1 One embodiment of suitable components that may be included within controller 211 is shown.

[0194] like Figure 1As shown in , the controller 211 may include a processor 212 and an associated memory 214, which is configured to perform a variety of computer-implemented functions (e.g., perform methods, steps, calculations, etc. disclosed herein). As used herein, the term "processor" refers not only to integrated circuits referred to in the art as included in a computer, but also to controllers, microcontrollers, microcomputers, programmable logic controllers (PLCs), application-specific integrated circuits (ASICs), field programmable gate arrays (FPGAs), and other programmable circuits. In addition, the memory 214 may generally include memory elements, including but not limited to computer-readable media (e.g., random access memory (RAM)), computer-readable non-volatile media (e.g., flash memory), compact disk read-only memory (CD-ROM), magneto-optical disk (MOD), digital versatile disk (DVD), and / or other suitable memory elements, or combinations thereof. In various embodiments, the controller 211 may define one or more of a full authority digital engine controller (FADEC), a propeller control unit (PCU), an engine control unit (ECU), or an electronic engine control system (EEC).

[0195] As shown, the controller 211 may include control logic 216 stored in the memory 214. The control logic 216 may include instructions that, when executed by the one or more processors 212, cause the one or more processors 212 to perform operations (e.g., those outlined in the method 1000 and its embodiments). Thus, the instructions may include one or more steps of the method 1000. Further, the operations may include performing one or more steps of the method 1000. In various embodiments, the memory 214 may also include one or more tables, charts, functions, or graphs storing data that may correspond the compressed air or coolant temperature or pressure to the desired function of the CCA heat exchanger 100 so as to produce the desired outlet temperature and pressure of the compressed air 101.

[0196] In addition, if Figure 1As shown in , the controller 211 may also include a communication interface module 230. In various embodiments, the communication interface module 230 may include associated electronic circuits for sending and receiving data. Therefore, the communication interface module 230 of the controller 211 can be used to receive data from the CCA heat exchanger 100, the coolant supply system 110, the compressor section 21, the combustion section 26 or the turbine section 31 or the bypass air flow path 48, 49. The data may include, but is not limited to, vibration data, surface temperature, fluid temperature, pressure and / or flow rate or rotation speed or acceleration. In addition, the communication interface module 230 can also be used to communicate with any other suitable component of the engine 10 including any number of sensors, which are configured to monitor one or more operating parameters of the engine 10, such as, but not limited to, parameters of compressed air or coolant (e.g., flow, pressure, volume, area or other geometry for calculating fluid flow, or fluid density, etc.). It should be appreciated that communication interface module 230 may be any combination of suitable wired and / or wireless communication interfaces, and thus may be communicatively coupled to one or more components of engine 10 via wired and / or wireless connections.

[0197] Method 1000 includes: at 1010, causing compressed air 99 with a defined inlet temperature and inlet pressure to flow from a core flow path 19 to a CCA heat exchanger 100 and be in thermal communication with a coolant 109 from a coolant supply system 110; and at 1020, causing compressed air 101 to flow from the CCA heat exchanger 100 to a hot section 33 (e.g., at secondary flow paths 27, 32), wherein the compressed air 101 defines an outlet temperature between approximately 2% and approximately 50% (inclusive) less than the inlet temperature of the compressed air 99, and an outlet pressure at the hot section 33 (e.g., at secondary flow paths 27, 32) that is approximately 90% or greater of the inlet pressure of the compressed air 99.

[0198] In various embodiments, the method 1000 further includes, at 1020, defining an outlet temperature between approximately 10% and approximately 50% less, inclusive, than the inlet temperature of the compressed air 99 at the hot section 33. In other various embodiments, the method 1000 further includes, at 1020, defining an outlet temperature between approximately 20% and approximately 50% less, inclusive, than the inlet temperature of the compressed air 99 at the hot section 33.

[0199] In various embodiments, flowing the compressed air 99 includes generating compressed air flows 81, 82 through the engine 10. In one embodiment, the method 1000 also includes generating compressed air flows 81, 82 defined at a high power state (e.g., takeoff power, or between 90% and 105% (inclusive) of a maximum rotational speed of one or more rotating shafts of the engine) at 1022; and extracting at least a portion of the compressed air flows 81, 82 from the compressor area 21 to the CCA loop 105 at 1024. Generating the compressed air flows 81, 82 at the high power state also includes operating the CCA heat exchanger 100 at 1026 to generate a maximum temperature increase at the coolant 109 defining the fuel. Generating the compressed air flows at the high power state may also include operating the CCA heat exchanger 100 to generate a maximum temperature increase at the coolant 109, which defines one or more of the bypass air 78, 79, the refrigerant, the supercritical fluid, the liquid metal, the fuel, the inert gas, or the compressed air, or a combination thereof.

[0200] In another embodiment, generating the compressed air flows 81, 82 further includes generating the compressed air flows 81, 82 at the compressor section 21 at a low or medium power state (e.g., ignition, ground idle, flight idle, cruise or approach state, or between 20% and up to 90% of the maximum speed of one or more rotating shafts of the engine) at 1023. Generating the compressed air flows at the low or medium power state also includes operating the CCA heat exchanger 100 to generate a maximum temperature increase at the coolant, which defines a fuel, a refrigerant, a supercritical fluid, a liquid metal, or an inert gas. Generating and providing the compressed air flows to the CCA heat exchanger 100 may also include interrupting the coolant flow 109 defining one or more of the bypass air flows 78, 79 at 1025 while the engine 10 defines one or more low or medium power states.

[0201] The method 1000 may also include adjusting the valve 210 at the CCA heat exchanger 100 at 1030 to define different temperatures and different pressures of the compressed air flow 101. The method 1000 may also include adjusting one or more of the inlet temperature and the inlet pressure of the compressed air 101 via adjusting the location in the compressor section 21 from which the compressed air 99 from the core flow path 19 is provided to the CCA heat exchanger 100 at 1040. For example, adjusting the location in the compressor section 21 from which the compressed air 99 is taken from the core flow path 19 includes adjusting or regulating the compressed air 99 entering the CCA heat exchanger 100 from compressed air 91 to compressed air 92. In various other embodiments, adjusting or regulating the compressed air flow 99 may include adjusting the location along the compressor section 21 from which the compressed air flow 91 is taken from the flow 81 in the core flow path 19. As yet another example, the method 1000 may include mixing the compressed air flows 91, 92 from the core flow path 19 at 1040.

[0202] The method 1000 may also include determining at 1050 a desired outlet temperature, outlet pressure, or both of the compressed air 101 based at least on an operating state of the engine 10. In various embodiments, the operating state of the engine 10 is based at least on a pressure, temperature, flow rate, or a combination thereof of the compressed air 81, 82 at the core flow path 19.

[0203] The method 1000 may also include adjusting, at 1060, one or more valves 210 at the CCA heat exchanger 100 to mix the coolant 109(a) at the first outlet temperature and / or the first outlet pressure with the coolant 109(d) at the inlet temperature and / or the inlet pressure to produce the coolant 111(a) at the desired outlet pressure and temperature, as described with respect to Figure 6 Shown and described.

[0204] As mentioned above about Figure 1-9 As described, the method 1000 may also include maintaining the temperature of the coolant 109 within operating constraints relative to a desired outlet temperature and / or pressure of the coolant flow 111 flowing out of the CCA heat exchanger 100 at 1070. For example, in various embodiments, the operating constraints include one or more of a maximum fuel temperature at the combustion section, a maximum lubricant temperature, or a minimized bypass air flow.

[0205] All or part of the CCA heat exchanger 100 may be part of a single integral component and may be manufactured by any number of processes generally known to those skilled in the art. In addition, the CCA heat exchanger 100 may be constructed as a single integral component, or multiple components, via any number of manufacturing processes referred to as "additive manufacturing" or "3D printing." In addition, any number of casting, machining, welding, brazing, or sintering processes, or any combination thereof, may be used to construct the CCA heat exchanger 100. In addition, the CCA heat exchanger 100 may be composed of one or more independent components that are mechanically connected (e.g., by using bolts, nuts, rivets, or screws, or welding or brazing processes, or combinations thereof), or positioned in space to achieve substantially similar geometric, aerodynamic, or thermodynamic results as if manufactured or assembled as one or more components. Non-limiting examples of suitable materials include high-strength steel or nickel-based and cobalt-based alloys, or combinations thereof.

[0206] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems, and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements that are insubstantially different from the literal language of the claims.

Claims

1. A gas turbine engine comprising: Fan assembly; a core engine disposed downstream of the fan assembly and comprising a core engine casing, a compressor section downstream of the fan assembly, a combustion section downstream of the compressor section, and a turbine section downstream of the combustion section; a fan bypass air flow path disposed downstream of the fan assembly and outside of the core engine casing; a core flow path disposed within the core engine casing and defined by the compressor section, the combustion section, and the turbine section a third flow bypass air flow path disposed between the fan bypass air flow path and the core flow path, which bypasses at least a portion of the core engine; and Cooling of cooling air CCA heat exchanger system, wherein the air flow from the fan assembly is divided into a first portion that enters the fan bypass airflow path and a second portion that enters the core engine casing, wherein the second portion is divided within the core engine casing between the core flow path and the third flow bypass air flow path, wherein the entirety of the air flow through the third flow bypass air flow path merges with the air flow of the fan bypass air flow path at an axial position axially before at least a portion of the turbine section, Wherein, at least a first portion of the CCA heat exchanger system is disposed in the third flow bypass air flow path.

2. The gas turbine engine according to claim 1, wherein: The third stream bypass airflow path is defined at least in part by the core engine casing from the compressor section to the fan bypass airflow path.

3. The gas turbine engine according to claim 1, wherein: The third flow bypass airflow path selectively allows a flow of compressed air from the compressor section to mix with the flow of air through the fan bypass airflow path.

4. The gas turbine engine according to claim 1, wherein: The third flow bypass airflow path is defined at least in part by the core engine casing from a compressor section downstream of a low pressure compressor of the compressor section and upstream of a high pressure compressor of the compressor section to the fan bypass airflow path.

5. The gas turbine engine according to claim 2, wherein: The third flow bypass airflow path is configured to completely or partially shut off the flow of compressed air from the compressor section from outflow to the fan bypass airflow path based on a first operating state of the gas turbine engine.

6. The gas turbine engine according to claim 5, wherein: The first operating state of the gas turbine engine is a high power state and wherein completely or partially shutting off the flow of compressed air from the compressor section from flowing out to the fan bypass airflow path increases thrust output of the gas turbine engine.

7. The gas turbine engine according to claim 2, wherein: The third flow bypass airflow path is configured to open a flow of compressed air from the compressor section to out to the fan bypass airflow path based on a second operating state of the gas turbine engine.

8. The gas turbine engine according to claim 7, wherein: The second operating state of the gas turbine engine is a low or medium power state and wherein opening the flow of compressed air from the compressor of the compressor section to flow out to the fan bypass airflow path reduces fuel consumption of the gas turbine engine.

9. The gas turbine engine according to claim 1, wherein: At least a second portion of the CCA heat exchanger system is disposed in the fan bypass airflow path downstream of the third stream bypass airflow path.

10. The gas turbine engine according to claim 9, further comprising: a coolant supply system that provides a coolant flow to the CCA heat exchanger system, Wherein, at least a first portion of the coolant supply system is disposed in the fan bypass air flow path upstream of a second portion of the CCA heat exchanger system.

11. The gas turbine engine according to claim 10, wherein: At least a second portion of the coolant supply system is disposed in the fan bypass airflow passage at an axial location where the third stream bypass airflow passage merges with the fan bypass airflow passage.

12. The gas turbine engine according to claim 9, wherein: A first portion of the CCA heat exchanger system is disposed in the third stream bypass airflow passage at an axial location where the third stream bypass airflow passage merges with the fan bypass airflow passage.

13. The gas turbine engine according to claim 10, wherein: At least a third portion of the CCA heat exchanger system is disposed at an inlet of the third stream bypass air flow path.

14. The gas turbine engine according to claim 2, wherein: The third stream bypass air flow path merges with the fan bypass air flow path and has an exhaust portion outside the core engine.

15. The gas turbine engine according to claim 14, wherein: The third stream bypass airflow path merges with the fan bypass airflow path at an axial location behind the entirety of the compressor section.

16. The gas turbine engine according to claim 15, wherein: The third stream bypass airflow path merges with the fan bypass airflow path at an axial location ahead of the entirety of the turbine section.

17. The gas turbine engine of claim 1, further comprising: a coolant supply system that provides a coolant flow to the CCA heat exchanger system, wherein at least a portion of the CCA heat exchanger system is disposed at the inlet of the third flow bypass air flow path, and wherein at least a portion of the coolant supply system is disposed at the same axial position in the fan bypass air flow path as a portion of the CCA heat exchanger system is disposed at the inlet of the third flow bypass air flow path.

18. The gas turbine engine of claim 1, wherein: An inlet portion of the third flow bypass air flow passage extends at an acute angle of less than 45° relative to an axial direction of the gas turbine engine.

19. The gas turbine engine of claim 1, further comprising: a secondary flow path in the combustion section through which a flow of compressed air from the CCA heat exchanger is provided, a hot section disposed downstream of the compressor section along the core flow path, wherein the flow of compressed air defines an inlet temperature and an inlet pressure from the core flow path at the compressor section, wherein the flow of compressed air defines an exit temperature at the secondary flow path at the hot section that is between 20% and 50% less than the inlet temperature, and wherein the flow of compressed air defines an outlet pressure at the secondary flow path that is greater than 90% of the inlet pressure of the flow of compressed air at the core flow path at the compressor section.

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