Thermal management methods and systems

Abstract

A thermal management method and structure for a vehicle is provided. The method includes extracting a compressed fluid flow from a compressor section of a propulsion system, wherein the compressed fluid flow includes a pressure parameter, and generating an output torque by expanding at least a portion of the compressed fluid flow through a turbine operably connected to a drive shaft. The turbine is located downstream of the compressor section and upstream of a cooling system.

Description

Technical Field

[0001] The present subject matter generally relates to thermal management methods and systems for propulsion systems and vehicles, such as aircraft. Background Art

[0002] Engines, such as geared turbines or variable pitch fans, face the challenge of thermal management of increasing heat loads. Conventional systems can use air flow to provide thermal attenuation of fuel or lubricants. However, this configuration may result in fan airflow obstruction, thereby reducing engine performance and efficiency. Conventional configurations may also not be sufficient to attenuate the heat loads associated with the reduction gearbox, variable pitch fan, or both. Therefore, there is a need for an improved thermal management system for lubrication systems and load devices. Summary of the invention

[0003] Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.

[0004] A thermal management method and structure for a vehicle is provided. The method includes extracting a compressed fluid flow from a compressor section of a propulsion system, wherein the compressed fluid flow includes a pressure parameter, and generating an output torque by expanding at least a portion of the compressed fluid flow through a turbine operably connected to a drive shaft. The turbine is located downstream of the compressor section and upstream of a cooling system.

[0005] These and other features, aspects and advantages of the present invention will be 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. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] A full and enabling disclosure of the present invention, 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:

[0007] Figure 1 is an exemplary embodiment of a vehicle including a propulsion system and a thermal management system according to aspects of the present disclosure; and

[0008] Figure 2-5 is an illustrative embodiment of a propulsion system and a thermal management system according to aspects of the present disclosure.

[0009] Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention. DETAILED DESCRIPTION

[0010] 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 to explain the present invention, rather than to limit the present invention. In fact, it will be apparent to those skilled in the art that various modifications and variations may be made to the present invention without departing from the scope or spirit of the present invention. For example, a feature shown or described as part of one embodiment may be used together with another embodiment to produce yet another embodiment. Therefore, the present invention is intended to encompass such modifications and variations within the scope of the appended claims and their equivalents.

[0011] As used herein, the terms “first,” “second,” and “third” are used interchangeably to distinguish one component from another and are not intended to indicate the position or importance of each component.

[0012] The terms "upstream" and "downstream" refer to the relative directions of the fluid flow in the fluid passage. For example, "upstream" refers to the direction from which the fluid is flowing, and "downstream" refers to the direction to which the fluid is flowing.

[0013] Provided herein are embodiments of propulsion systems, vehicles, and thermal management systems that can improve overall system and vehicle efficiency, such as by utilizing relatively high pressure fluid from a compressor section of a propulsion system rather than utilizing a pressure regulator or releasing fluid to, for example, atmospheric conditions. Thus, the work extracted from the air exhausted from the propulsion system can be maximized. The embodiments provided herein can further improve the heat transfer from the lubricant in the lubricant system. Further, the embodiments provided herein can improve the heat transfer from the lubricant and additionally from one or more load devices (such as a computing system, an environmental control system, or a motor). In addition, or alternatively, the cooling fluid at the fluid circuit can be independently adjusted relative to the operating conditions at the propulsion system, such as by a flow control device and / or a flow device. The embodiments provided herein can include specific series or parallel flows and components to advantageously improve heat transfer and overall system efficiency. Certain embodiments can allow for substantially independent adjustability of heat exchange fluid relative to propulsion system operating conditions, lubricant system operating conditions, or load system operating conditions.

[0014] Now refer to the accompanying drawings, Figure 1In, an exemplary embodiment of a vehicle 100 including a propulsion system 10 and a thermal management system 200 according to aspects of the present disclosure is provided. In one embodiment, the vehicle 100 is an aircraft including an aircraft structure or frame 105. The frame 105 includes a fuselage 110, to which wings 120 and a tail 130 are attached. The propulsion system 10 according to aspects of the present disclosure is attached to one or more portions of the frame. In various embodiments, the thermal management system 200 is a system configured to ideally distribute heat loads, such as adding or removing heat from one or more fluids or structures (such as, but not limited to, an oxidizer at a propulsion system, a fuel, a lubricant, a hydraulic fluid, a pneumatic fluid, or a cooling fluid for a motor, electronic equipment, a computing system, an environmental control system, a gear assembly, or other system or structure).

[0015] In some cases, propulsion system 10 is attached to the rear of fuselage 110. In some other cases, propulsion system 10 is attached below, above, or through portions of wing 120 and / or tail 130. In various embodiments, propulsion system 10 is attached to frame 105 via a pylon or other mounting structure. In still other embodiments, propulsion system 10 is housed within a frame, such as may be exemplified in certain supersonic military or commercial aircraft.

[0016] Various embodiments of vehicle 100 include computing system 140, such as avionics or other electronic equipment or computing devices configured to control vehicle 100 or propulsion system 10. Vehicle 100 may also include environmental control system (ECS) 150, such as to provide thermally conditioned air to a cabin of the vehicle, computing system 140, vehicle surface anti-icing system 160, propulsion system anti-icing system, or other systems of vehicle 100 or propulsion system 10. In various embodiments such as described herein, thermal management system 200 may be configured to provide thermally conditioned fluid to one or more of the systems described herein.

[0017] Reference now Figure 2-5 , providing transportation 100( Figure 1) is an exemplary schematic embodiment of a propulsion system 10 and a thermal management system 200 at a position. The propulsion system 10 can generally be configured as a Brayton cycle machine. Specific embodiments of the propulsion system 10 can be configured as a turbine, a ramjet, or a scramjet. Other specific embodiments of the propulsion system 10 may include a turbine configured as a turbofan, a turboprop, a turbojet, a turboshaft, a propeller fan, or an open rotor engine. Certain embodiments of the propulsion system 10 include a fan section 12, a compressor section 20, a combustion section or a heat addition system 26, an expansion section 30, and an exhaust section 36 arranged in series flow. The fan section 12 includes one or more stages of rotors and blades. One or more fan streams 14 are located downstream of one or more stages of rotors and blades. In certain embodiments, the fan stream 14 is located behind the first stage fan rotor, such as generally defining a fan bypass of a turbofan engine. In yet certain embodiments, one or more fan flows 14 are located behind a second or more fan rotor (e.g., a low pressure compressor or supercharger), such as to typically aerodynamically define a third flow between a fan flow defining a fan bypass and a main or core flow path through the compressor section 20, heat addition system 26, and expansion section 30.

[0018] The compressor section 20, the heat addition system 26 and the expansion section 30 are generally positioned in a series aerodynamic flow arrangement. The compressor section 20, the heat addition system 26 and the expansion section 30 can together define the core engine or gas generator of the propulsion system 10. In various embodiments, the heat addition system 26 can be configured as a deflagrative combustion system or a detonative combustion system. The heat addition system 26 may include any suitable type of system for receiving liquid and / or gas fuel flow and generating hot gases, including but not limited to annular, can-annular, can, trapped vortex, volute or vortex, rotating detonation, pulse detonation, subsonic or supersonic combustion systems.

[0019] In certain embodiments, such as described herein, the compressor section 20 includes a high pressure compressor that is in direct series flow arrangement with the heat addition system 26 and the high pressure turbine 32 of the expansion section 30. The low pressure turbine 34 of the expansion section 30 may be operably coupled to the fan section 12 to drive one or more stages of the fan section 12. In certain embodiments not depicted, the propulsion system 10 may include an intermediate pressure compressor aerodynamically positioned between the fan section 12 and the high pressure compressor, and an intermediate pressure turbine aerodynamically positioned between the high pressure turbine 32 and the low pressure turbine 34.

[0020] Still reference Figure 2-5, the thermal management system 200 includes a walled conduit 205, such as a pipe, manifold, or other suitable structure, forming a fluid circuit 210, which is configured to be in fluid communication to receive a fluid from the compressor section 20 of the propulsion system 10. The fluid is typically an oxidant, such as compressed air, from the propulsion system 10. In certain embodiments, the fluid is extracted from a main or core flow path of the propulsion system 10. In a particular embodiment, the fluid is extracted from one or more stages at or after the high pressure compressor of the compressor section 20.

[0021] The thermal management system 200 also includes a flow control device 220 located at the fluid circuit 210 downstream of the compressor section 20. A turbine 230 is located at the fluid circuit 210 downstream of the compressor section 20. In a particular embodiment, the flow control device 220 and the turbine 230 are integrated into a variable area turbine nozzle (VATN). The flow control device 220 and the turbine 230, which together define the VATN, are together configured to control the mass flow entering or through the turbine 230. In one embodiment, the flow control device 220 is a variable area structure at the inlet of the turbine 230, such as a variable area nozzle. However, in other embodiments, the flow control device 220 is a separate flow control structure that is configured to regulate the mass flow through the turbine 230. In certain embodiments, the turbine 230 is located downstream of the flow control device 220.

[0022] In certain embodiments, a flow device 240 is located at the fluid circuit 210 downstream of the flow control device 220 and the turbine 230. The flow control device 220 is configured to provide a first portion 211 of the fluid to the turbine 230 while providing a second portion 212 of the fluid from the flow control device 220 to the flow device 240. The flow device 240 is configured to combine, mix, or draw together the flows from the first portion 21 and the second portion 212. In various embodiments, the flow device 240 is a fluid mixer, ejector, or other suitable device configured to allow the relatively high pressure flow of the fluid at the second portion 212 to draw together the relatively low pressure flow from the first portion 211 through the fluid circuit 210 as a combined flow of fluid schematically depicted at 213. The fluid circuit 210 is configured to provide the first portion 211 of the fluid from the turbine 230 to the flow device 240. The heat load 250 is positioned in thermal communication with the fluid circuit 210 downstream of the turbine 230.

[0023] In various embodiments, flow control device 220 is a diverter valve or other suitable mechanism configured to direct the ratio or proportion of first portion 211 and second portion 212 to turbine 230 and flow device 240, respectively. The pressurized fluid flow from compressor section 20 is used to drive turbine 230, such as depicted at first portion 211. In certain embodiments, such as in Figure 2-4 As depicted in FIG. 1 , the expanded decompression fluid schematically depicted at 211a is then transferred from the turbine 230 to the flow device 240 along the fluid circuit 210. In yet certain embodiments, the expanded decompression fluid 211a is transferred from the turbine 230 along the fluid circuit 210 to be in thermal communication with the heat load 250. After being in thermal communication with the heat load 250, the fluid schematically depicted by arrow 211b may be provided to the flow device 240, for example Figure 3 In another embodiment, the fluid 211b can be discharged or dumped into, for example, the engine compartment, under the hood, or into the atmosphere, for example Figure 5 211c in FIG. 2. Flow device 240 is configured to receive a first portion 211 of the fluid from flow control device 220 and a second portion 212 of the fluid from turbine 230. In certain embodiments, flow control device 220 is configured to provide the first portion 211 of the fluid to turbine 230 while providing the second portion 212 of the fluid to flow device 240, while the second portion 212 of the fluid bypasses turbine 230.

[0024] It should be understood that conventional thermal management systems typically utilize valves to restrict or regulate flow from the engine compressor to the air cycle machine compressor. Such systems typically result in relatively large pressure losses across the valve. Such pressure losses result in significant inefficiencies in the engine and thermal management system by compressing air at the engine compressor and then releasing excess pressure to control or regulate flow to the air cycle machine compressor. In contrast, embodiments of the present disclosure utilize excess pressure at the turbine 230 to produce useful work, such as provided herein.

[0025] The first portion 211 of the fluid can generally include a first fluid property that is different from the second portion 212 of the fluid having a second fluid property. In various embodiments, the first fluid property includes a higher fluid pressure or flow rate than the second fluid property. The flow device 240 is configured to receive the respective portions 211, 212 of the fluid and provide a desired fluid downstream along the fluid circuit 210 (e.g., having a third fluid property, depicted at fluid 213 of the fluid circuit 210, that is different from the first and second fluid properties of the fluids 211 and 212, respectively).

[0026] refer to Figure 2-5In various embodiments, turbine 230 is operably coupled to turbine 260 located at fluid circuit 210. Turbine 260 includes a compressor 262 coupled to a turbine 266 via a drive shaft 264. In a particular embodiment, turbine 260 is part of an air circulation system. Compressor 262 is located at fluid circuit 210 downstream of flow device 240. In a particular embodiment, turbine 230 is operably coupled to drive shaft 264 to provide energy to drive compressor 262. In yet another particular embodiment, turbine 230 and turbine 266 of turbine 260 together provide energy to drive compressor 262.

[0027] It should be appreciated that flow control device 220 allows fluid circuit 210 to selectively adjust the ratio or proportion of first portion 211 and second portion 212 to turbine 230 and flow device 240, respectively. Compared to a pressure regulator configured to reduce pressure, resulting in a loss of work or energy to propulsion system 10 and thermal management system 200, flow control device 220, such as defining a diverter valve or other suitable device for selectively adjusting the proportion of fluid flowing to two or more circuits (e.g., first portion 211 and second portion 212), allows turbine 230 to utilize relatively high pressure fluid from compressor section 20 to at least partially drive turbine 260. Turbine 230 may correspond to a desired fluid characteristic (e.g., a desired second fluid characteristic) of the fluid discharged from turbine 230 to flow device 240. Additionally or alternatively, turbine 230 may correspond to a desired energy output of turbine 260 to which turbine 230 may be operably coupled.

[0028] Reference now Figure 2-5 In various embodiments, the vehicle 100, the propulsion system 10, and the thermal management system 200 include a heat exchanger 310 located at the fluid circuit 210 downstream of the compressor 262 and upstream of the turbine 266 of the turbine 260. In various embodiments, the heat exchanger 310 is positioned to be thermally connected to one or more fan flows of the propulsion system 10. As described above, one or more fan flows may include a fan bypass flow, or a third flow located between the fan flow and the core flow path. It should be understood that the third flow refers to an air flow configured to recover fluid energy to generate a portion of the total thrust of the propulsion system. In one embodiment, a portion of the total thrust generated by the third flow may include a dedicated exhaust nozzle at the outlet end. In another embodiment, a portion of the total thrust generated by the third flow may be mixed with the fan bypass flow. In yet another embodiment, a portion of the total thrust generated by the third flow may be mixed with the core flow path downstream of the heat addition system and discharged through the exhaust section. Various embodiments of the third flow are configured to generate less than 50% of the total thrust of the propulsion system.

[0029] The heat exchanger 310 is configured to remove thermal energy or heat from the fluid circuit 210. In certain embodiments, the heat exchanger 310 is configured to input thermal energy or heat to the fuel circuit, such as heating the fuel flow before injecting the fuel into the heat addition or combustion section. In certain other embodiments, the heat exchanger 310 is configured to input thermal energy or heat to the air flow passing through one or more fan streams 14. In various other embodiments, the heat exchanger 310 includes a fuel circuit that is positioned in thermal communication with the fluid circuit 210.

[0030] Reference now Figure 3 and Figure 5 In certain embodiments, the vehicle 100, the propulsion system 10, and the thermal management system 200 include a heat exchanger 315 located at the fluid circuit 210 downstream of the compressor section 20 and upstream of the flow control device 220. In various embodiments, the heat exchanger 315 is positioned to be thermally connected to one or more fan streams 14 of the propulsion system 10, such as described herein. The heat exchanger 315 is configured to remove thermal energy or heat from the fluid circuit 210. In certain other embodiments, the heat exchanger 315 is configured to input thermal energy or heat to the fluid flow passing through the one or more fan streams 14. In a particular embodiment, the heat exchanger 315 is a pre-cooler located at the fluid circuit 210 to remove thermal energy or heat from the fluid before providing the fluid to the flow control device 220 and the turbine 230. Although with respect to Figure 3 and Figure 5 While depicted, it should be understood that other embodiments depicted and described herein may include a heat exchanger 315 defining a pre-cooler at the fluid circuit 210 upstream of the flow control device 220 .

[0031] Reference now Figure 2-5 In various embodiments, the heat load 250 includes a lubricant heat exchanger 320 positioned at the fluid circuit 210 downstream of the turbine 230. In other various embodiments, the heat load 250 includes a lubricant circuit 251, which is positioned in thermal communication with the fluid circuit 210. The lubricant circuit 251 includes oil or an oil-based fluid from a lubricant system 252. The lubricant system 252 may include any suitable system, including a pump, a scavenging device, and a heat exchanger, which is configured to provide lubricant to one or more bearing assemblies, gear assemblies, actuators, or other systems of the propulsion system 10 or vehicle 100. The lubricant circuit 251 is arranged to have a heat exchange relationship with the fluid circuit 210 at the lubricant heat exchanger 320.

[0032] In certain embodiments, the lubricant heat exchanger 320 is configured to receive or remove heat or thermal energy from the lubricant circuit 251 and provide heat or thermal energy to the fluid circuit 210, or in particular, the first portion 211 of the fluid downstream of the turbine 230. The flow control device 220 may be configured to adjust the amount of the first portion 211 of the fluid provided to the turbine 230 and the heat load 250 based on the desired heat transfer between the fluid circuit 210 and the lubricant circuit 251.

[0033] In some embodiments, for example Figure 2-5 As depicted in FIG. 2 , heat load 250 is positioned in thermal communication with fluid circuit 210 downstream of turbine 230. In certain embodiments, heat load 250 including lubricant system 252 is positioned in thermal communication with fluid circuit 210 downstream of turbine 230. Figure 2-5 In yet the particular embodiment shown, a heat load 250 including a lubricant system 252 is positioned in thermal communication with the fluid circuit 210 downstream of the turbine 230 and upstream of the flow device 240 .

[0034] Reference now Figure 4 In various embodiments, the heat load 250 is positioned in thermal communication with the fluid circuit 210 downstream of the turbine 260. In certain embodiments, such as described above, the heat load 250 includes a lubricant system 252, which is positioned in thermal communication with the fluid circuit 210 downstream of the turbine 260. In still other various embodiments, the heat load 250 includes a load heat exchanger 330, which is positioned in thermal communication with the fluid circuit 210 downstream of the turbine 260. In certain embodiments, the load heat exchanger 330 includes a motor, a computing system, or an environmental control system (ECS) (e.g., see Figure 1 The load heat exchanger 330 may be configured to provide fluid from the fluid circuit 210 as a cooling fluid that is thermally connected to the motor, computing system, or environmental control system, or one or more of its fluids. Various embodiments of the motor may include an electric motor and / or a generator, a hybrid power plant, etc. In various embodiments, the computing system may include avionics, engine control, vehicle control system, or other electronic equipment including one or more processors, storage devices, communication devices, circuits, or other electrical or electronic systems. In yet other embodiments, the ECS may include fluids configured for use in a cabin of a vehicle, a heat transfer fluid for a vehicle, or one or more of other fluid devices.

[0035] Embodiments of heat load 250 may include a first heat load positioned in thermal communication with fluid circuit 210 downstream of turbine 260 and a second heat load positioned in thermal communication with fluid circuit 210 downstream of turbine 230 and upstream of flow device 240. In certain embodiments, the first heat load includes a load heat exchanger 330 such as described herein. In certain embodiments, the second heat load includes lubricant heat exchanger 320 and lubricant system 252.

[0036] Various embodiments of the thermal management system 200 may include one or more valves 290 to separate the fluid at the fluid circuit 210 into a first flow 221 and a second flow 222, such as Figure 4 As shown. The system 200 may further include one or more second valves 291 to reconnect the streams 221, 222. The valve 290 is located upstream of the lubricant heat exchanger 320 and the load heat exchanger 330. The second valve 291 is located downstream of the lubricant heat exchanger 320 and the load heat exchanger 330. In certain embodiments, the system 200 includes an exhaust groove 295, and the fluid from the fluid circuit 210 can be arranged at the exhaust groove 295. The exhaust groove 295 may include one or more of the exhaust grooves at the turbine 260, at the propulsion system 10, or at another exhaust groove or the surrounding environment.

[0037] A thermal management method for a vehicle is provided herein. The method may be performed by an aircraft 100, a propulsion system 10, or a thermal management system 200, for example Figure 1-5 The method may provide one or more benefits, such as described herein with respect to the specific positioning, arrangement, fluid communication, and thermal communication provided in various embodiments.

[0038] The method includes extracting a compressed fluid flow from a compressor section of a propulsion system, such as described with respect to extracting a fluid flow from compressor section 20 to fluid circuit 210. The compressed fluid flow includes a pressure parameter. The pressure parameter is a measurement, calculation, or signal representing the pressure of the compressed fluid. The method also includes generating an output torque by expanding at least a portion of the compressed fluid flow through a turbine operably connected to a drive shaft, such as described with respect to a first portion 211 of the fluid flow expanded via turbine 230. The turbine is located downstream of the compressor section and upstream of a cooling system, such as described with respect to turbine 260.

[0039] In one embodiment, the method includes determining a pressure requirement of a compressed fluid flow at a cooling system and flowing or otherwise providing the compressed fluid flow to the cooling system. Figure 2-5, a cooling system, such as turbine 260, is configured to operate with a compressed fluid flow having a value corresponding to a pressure requirement. In one embodiment, the pressure requirement is a pressure range over which the cooling system (e.g., turbine 260) is operable. A minimum pressure may be required to operate the cooling system. A maximum pressure may be required to maintain desired operability, performance, efficiency, or structural life and durability.

[0040] In various embodiments, generating output torque by expanding at least a portion of the compressed fluid flow through the turbine includes flowing or otherwise providing a first portion of the compressed fluid flow to a cooling system from upstream of the turbine and providing a second portion of the compressed fluid flow to the turbine, such as by diverting, diverting, or otherwise allocating a first portion 211 of the fluid to a turbine 230 and providing a second portion 212 of the fluid to a flow device 240 with respect to a flow control device 220, such as described herein. In one embodiment, the second portion of the compressed fluid flow corresponds to a pressure requirement at the cooling system. For example, with reference to Figure 2-5 , the flow control device 220 can divert the fluid flow because the second portion 212 substantially has the pressure required to operate the turbine 260. In yet another embodiment, the first portion of the compressed fluid flow corresponds to the difference between the pressure requirement at the cooling system and the pressure parameter of the compressed fluid flow from the compressor section. In this way, the first portion 211 of the compressed fluid flow corresponding to the pressure magnitude exceeding the pressure requirement can be directed to the turbine 230, and the second portion 212 of the compressed fluid flow corresponding to the pressure magnitude required to operate the turbine 260 is directed to the turbine 260. The method can also include combining the first and second portions of the compressed air flow, such as described with respect to the flow device 240, and providing the combined compressed air flow to the cooling system.

[0041] In various embodiments, the method includes generating an output torque by expanding at least a portion of the compressed fluid flow through a turbine includes converting an overpressure of the compressed fluid flow from the compressor section into an output torque at the drive shaft, such as described with respect to the thermal management system 200. In one embodiment, converting the overpressure of the compressed fluid flow corresponds to a difference between a pressure requirement of the compressed fluid flow at the cooling system and a pressure parameter of the compressed fluid flow at the compressor section.

[0042] In yet other embodiments, the method includes operating the turbine at the cooling system with output torque from the turbine, such as Figure 2-5In some embodiments, operating the turbine at the cooling system includes flowing or otherwise providing a compressed fluid to a compressor at the turbine, a heat exchanger located downstream of the compressor, and an expander located downstream of the compressor in a series flow arrangement. In certain embodiments, the method includes flowing or otherwise providing the compressed fluid flow to a heat load located downstream of the expander, such as Figure 2-5 The heat load described in 250.

[0043] In some embodiments, the method further includes regulating a mass flow rate of the compressed fluid flow to the turbine based at least on a flow control device (e.g., flow control device 220) upstream of the turbine (e.g., turbine 230) and downstream of a compressor section (e.g., compressor section 20 at propulsion system 10). In one embodiment, regulating the mass flow rate of the compressed fluid flow to the turbine includes flowing or otherwise providing a first portion of the compressed fluid flow to the turbine from the flow control device, then expanding a second portion of the compressed fluid flow through the turbine, and providing the second portion of the compressed fluid flow from the flow control device to a cooling system, e.g., with respect to Figure 2-5 As described. In various embodiments, adjusting the mass flow rate of the compressed fluid flow to the turbine includes flowing or otherwise providing a first portion of the compressed fluid flow from a flow control device to the turbine, wherein the first portion of the compressed fluid flow corresponds to a difference between a pressure requirement at a cooling system and a pressure parameter of the compressed fluid flow from the compressor section, and flowing or otherwise providing a second portion of the compressed fluid flow from the flow control device to the cooling system, wherein the second portion of the compressed fluid flow corresponds to the pressure requirement at the cooling system. In a specific embodiment, adjusting the mass flow rate of the compressed fluid flow to the turbine includes adjusting an area of ​​a variable area turbine nozzle of the turbine.

[0044] In various embodiments, extracting a compressed fluid flow from a compressor section of a propulsion system includes extracting the compressed fluid flow from two or more stations at the compressor section. Each station provides a respective pressure parameter that is different from one another. In one embodiment, the method includes adjusting which station at the compressor section the compressed fluid flow is extracted from. The station at the compressor section from which the compressed fluid flow is extracted may be adjusted based at least on a pressure requirement at a cooling system and an operating mode of the propulsion system.

[0045] Embodiments of the propulsion system 10, vehicle 100, and thermal management system 200 provided herein can improve system efficiency, for example by utilizing fluid pressure from a compressor section of the propulsion system, or in particular from a high-pressure compressor, rather than utilizing a pressure regulator or releasing the fluid to, for example, atmospheric conditions. The embodiments provided herein can further improve heat transfer from a lubricant at a lubricant system. Further, the embodiments provided herein can improve heat transfer from the lubricant and additionally from one or more load devices (e.g., a load heat exchanger). Additionally or alternatively, the cooling fluid at the fluid circuit 210 can be independently adjustable relative to operating conditions at the propulsion system 10 (e.g., via a flow control device 220 and / or a flow device 240).

[0046] One or more components of the propulsion system 10 and thermal management system 100 described herein may be manufactured or formed using any suitable process, such as an additive manufacturing process, such as a 3-D printing process. Using such a process may allow these components to be formed integrally, as a single integral component, or as any suitable number of subcomponents, or at a scale and complexity not previously allowed or contemplated in the art. In particular, the additive manufacturing process may allow these components to be formed integrally and include a variety of features that are not possible when using existing manufacturing methods. For example, the additive manufacturing methods described herein may allow the turbine 230 and the flow control device 220 to be manufactured as a single integral component. In further embodiments, the additive manufacturing methods described herein allow the turbine 230, the flow control device 220, and at least a portion of the duct 205 to be manufactured with unique features, configurations, thicknesses, materials, densities, fluid passages, headers, and mounting structures that may not be possible or practical using existing manufacturing methods.

[0047] Suitable additive manufacturing techniques according to the present disclosure include, for example, fused deposition modeling (FDM), selective laser sintering (SLS), 3D printing (e.g., by inkjet, laser jetting, and binder jetting), stereolithography (SLA), direct selective laser sintering (DSLS), electron beam sintering (EBS), electron beam melting (EBM), laser engineered net shaping (LENS), laser net shaping manufacturing (LNSM), direct metal deposition (DMD), digital light processing (DLP), direct selective laser melting (DSLM), selective laser melting (SLM), direct metal laser melting (DMLM) and other known processes. Suitable powder materials for making the structure provided herein as a whole, a single structure, or a structure of the scale and complexity provided herein include metal alloys, polymers, or ceramic powders. Exemplary metal powder materials are stainless steel alloys, cobalt-chromium alloys, aluminum alloys, titanium alloys, nickel-based superalloys, and cobalt-based superalloys. In addition, suitable alloys may include those designed to have good oxidation resistance, known as "superalloys", which have acceptable strength under high temperature operation of gas turbine engines, such as Hastelloy, Inconel alloys (e.g., IN738, IN792, IN939), Rene alloys (e.g., Rene N4, Rene N5, Rene 80, Rene 142, Rene 195), Haynes alloys, Mar M, CM 247, CM 247LC, C263, 718, X-850, ECY 768, 282, X45, PWA 1483, and CMSX (e.g., CMSX-4) single crystal alloys. The fabricated objects of the present disclosure may be formed with one or more selected crystalline microstructures, such as directionally solidified ("DS") or single crystal ("SX").

[0048] This written description uses examples to disclose the invention, including the best mode, and also to enable a 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 a person 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 with insubstantial differences from the literal language of the claims.

[0049] Further aspects of the invention are provided by the subject matter of the following clauses:

[0050] 1. A thermal management method for a vehicle, the method comprising extracting a compressed fluid flow from a compressor section of a propulsion system, wherein the compressed fluid flow includes a pressure parameter; and generating an output torque by expanding at least a portion of the compressed fluid flow through a turbine operably connected to a drive shaft, wherein the turbine is positioned downstream of the compressor section and upstream of a cooling system.

[0051] 2. A method as described in any one or more of the clauses herein, the method comprising determining a pressure requirement of a compressed fluid flow at a cooling system; and providing the compressed fluid flow to the cooling system, wherein the compressed fluid flow comprises the pressure requirement.

[0052] 3. A method as described in any one or more of the clauses herein, wherein generating an output torque by expanding at least a portion of a compressed fluid flow through a turbine comprises providing a first portion of the compressed fluid flow to the turbine; and providing a second portion of the compressed fluid flow to a cooling system from upstream of the turbine.

[0053] 4. A method as described in any one or more of the clauses herein, wherein the second portion of the compressed fluid flow corresponds to a pressure requirement at the cooling system.

[0054] 5. A method as described in any one or more of the clauses herein, wherein the first portion of the compressed fluid flow corresponds to a difference between a pressure requirement at the cooling system and a pressure parameter of the compressed fluid flow from the compressor section.

[0055] 6. A method as described in any one or more of the clauses herein, comprising combining the first portion and the second portion of the compressed air flow.

[0056] 7. A method as described in any one or more of the clauses herein, comprising providing a combined compressed air flow to a cooling system.

[0057] 8. A method as described in any one or more of the clauses herein, wherein generating the output torque by expanding at least a portion of the compressed fluid flow through the turbine includes converting an overpressure of the compressed fluid flow from the compressor section into the output torque at the drive shaft.

[0058] 9. A method as described in any one or more of the clauses herein, wherein the overpressure of the converted compressed fluid flow corresponds to the difference between the pressure requirement of the compressed fluid flow at the cooling system and the pressure parameter of the compressed fluid flow at the compressor section.

[0059] 10. A method as defined in any one or more of the clauses herein, comprising operating a turbine in a cooling system via output torque from the turbine.

[0060] 11. A method as described in any one or more of the clauses herein, wherein operating a turbine at a cooling system includes providing a compressed fluid flow to a compressor at the turbine, a heat exchanger located downstream of the compressor, and an expander located downstream of the compressor in a series flow arrangement.

[0061] 12. A method as described in any one or more of the clauses herein, comprising providing a compressed fluid flow to a heat load located downstream of an expander.

[0062] 13. A method as described in any one or more of the clauses herein, comprising regulating a mass flow rate of a flow of compressed fluid to the turbine based at least on a flow control device upstream of the turbine and downstream of the compressor section.

[0063] 14. A method as described in any one or more of the clauses herein, wherein regulating the mass flow rate of a compressed fluid flow to a turbine comprises providing a first portion of the compressed fluid flow to the turbine from a flow control device, and then expanding a second portion of the compressed fluid flow through the turbine; and providing a second portion of the compressed fluid flow from the flow control device to a cooling system.

[0064] 15. A method as described in any one or more of the clauses herein, wherein regulating the mass flow rate of a compressed fluid flow to a turbine comprises providing a first portion of the compressed fluid flow to the turbine from a flow control device, wherein the first portion of the compressed fluid flow corresponds to a difference between a pressure requirement at a cooling system and a pressure parameter of the compressed fluid flow from a compressor section; and providing a second portion of the compressed fluid flow to the cooling system from the flow control device, wherein the second portion of the compressed fluid flow corresponds to the pressure requirement at the cooling system.

[0065] 16. A method as described in any one or more of the clauses herein, wherein adjusting the mass flow rate of the compressed fluid flow to the turbine comprises adjusting an area of ​​a variable area turbine nozzle of the turbine.

[0066] 17. A method as described in any one or more of the clauses herein, wherein extracting the compressed fluid flow from the compressor section of the propulsion system includes extracting the compressed fluid flow from two or more stations at the compressor section, wherein each station provides a respective pressure parameter that is different from one another.

[0067] 18. A method as described in any one or more of the clauses herein, comprising regulating from which station at the compressor section the compressed fluid flow is extracted.

[0068] 19. A method as described in any one or more of the clauses herein, wherein the station at the compressor section from which the compressed fluid flow is extracted is regulated based at least on the pressure requirement at the cooling system and the operating mode of the propulsion system.

[0069] 20. A method as described in any one or more of the clauses herein, comprising providing a flow of compressed fluid to a heat load downstream of a turbine.

[0070] 21. A thermal management system for an aircraft, the system being configured to perform the steps of the method of any clause herein.

[0071] 22. A thermal management system comprising a propulsion system having a compressor section and a turbine section in a series flow arrangement; a fluid circuit extending in fluid communication from the compressor section to a flow control device, and wherein a first portion of the fluid circuit extends in fluid communication from the flow control device to the turbine, and wherein a second portion of the fluid circuit extends in fluid communication from the flow control device to the flow device, and wherein the fluid circuit is configured to receive a fluid flow from the compressor section of the propulsion system and provide a first portion of the fluid flow for expansion through the turbine, and wherein the fluid flow expanded through the turbine is in thermal communication with a heat load via the fluid circuit, and wherein a second portion of the fluid flow is provided to the flow device bypassing the turbine.

[0072] 23. A thermal management system as described in any one or more of the clauses herein, wherein the fluid circuit extends into fluid communication with a cooling system downstream of the turbine.

[0073] 24. A thermal management system as described in any one or more of the clauses herein, wherein the fluid circuit extends in fluid communication from the flow device to the cooling system.

[0074] 25. A thermal management system as described in any one or more of the clauses herein, wherein the fluid circuit extends from the cooling system to provide a fluid flow in thermal communication with the heat load.

[0075] 26. A thermal management system as described in any one or more of the clauses herein, wherein the cooling system is a turbomachine including a turbine operably coupled to a compressor.

[0076] 26. An aircraft comprising a thermal management system as claimed in any of the clauses herein.

[0077] 27. An aircraft configured to perform one or more steps of the method of any one or more of the clauses herein.

Claims

1. A thermal management method for an aircraft, characterized in that: The method comprises: extracting a compressed fluid flow from a compressor section of a propulsion system, wherein the compressed fluid flow includes a pressure parameter; producing an output torque by expanding at least a portion of the compressed fluid flow through a turbine operatively connected to a drive shaft, wherein the turbine is positioned downstream of the compressor section and upstream of a cooling system; determining a pressure requirement for the compressed fluid flow at the cooling system; and providing said at least a portion of said compressed fluid flow to said cooling system, Wherein the compressed fluid flow at the cooling system is at a value corresponding to the pressure requirement.

2. The method according to claim 1, characterized in that wherein generating the output torque by expanding the at least a portion of the compressed fluid flow through the turbine comprises: providing a first portion of the compressed fluid flow to the turbine; and A second portion of the compressed fluid flow is provided to the cooling system upstream of the turbine.

3. The method according to claim 2, characterized in that Wherein the second portion of the compressed fluid flow corresponds to a pressure requirement at the cooling system.

4. The method according to claim 3, characterized in that Wherein the first portion of the compressed fluid flow corresponds to a difference between the pressure requirement at the cooling system and the pressure parameter of the compressed fluid flow from the compressor section.

5. The method according to claim 4, characterized in that The method comprises: The first portion and the second portion of the compressed fluid flow are combined.

6. The method according to claim 5, characterized in that The method comprises: The combined compressed air flow is provided to the cooling system.

7. The method according to claim 1, characterized in that Wherein generating the output torque by expanding the at least a portion of the compressed fluid flow through the turbine includes converting an overpressure of the compressed fluid flow from the compressor section into the output torque at the drive shaft.

8. The method according to claim 7, characterized in that Wherein the overpressure at which the compressed fluid flow is switched corresponds to a difference between a pressure requirement of the compressed fluid flow at the cooling system and the pressure parameter of the compressed fluid flow at the compressor section.

9. The method according to claim 1, characterized in that: The method comprises: A turbine is operated in the cooling system via the output torque from the turbine.

10. The method according to claim 9, characterized in that Wherein operating the turbine at the cooling system comprises: The compressed fluid flow is provided in a series flow arrangement to a compressor at the turbine, a heat exchanger downstream of the compressor, and an expander downstream of the compressor.

11. The method according to claim 10, characterized in that The method comprises: The compressed fluid flow is provided to a heat load downstream of the expander.

12. The method according to claim 1, characterized in that The method comprises: A mass flow rate of the compressed fluid flow to the turbine is adjusted based on at least flow control devices upstream of the turbine and downstream of the compressor section.

13. The method according to claim 12, characterized in that Wherein regulating the mass flow rate of the compressed fluid flow to the turbine comprises: providing a first portion of the compressed fluid flow from the flow control device to the turbine and then expanding a second portion of the compressed fluid flow through the turbine; A second portion of the compressed fluid flow is provided from the flow control device to the cooling system.

14. The method according to claim 12, characterized in that wherein regulating the mass flow rate of the compressed fluid flow to the turbine includes providing a first portion of the compressed fluid flow from the flow control device to the turbine, wherein the first portion of the compressed fluid flow corresponds to a difference between the pressure requirement at the cooling system and the pressure parameter of the compressed fluid flow from the compressor section; and A second portion of the compressed fluid flow is provided from the flow control device to the cooling system, wherein the second portion of the compressed fluid flow corresponds to a pressure requirement at the cooling system.

15. The method according to claim 12, characterized in that Wherein adjusting the mass flow rate of the compressed fluid flow to the turbine includes adjusting an area of ​​a variable area turbine nozzle of the turbine.

16. The method according to claim 1, characterized in that Wherein extracting the compressed fluid flow from the compressor section of the propulsion system includes extracting the compressed fluid flow from two or more stations at the compressor section, wherein each station provides a respective pressure parameter that is different from one another.

17. The method according to claim 16, characterized in that The method comprises: The station at the compressor section from which the compressed fluid flow is extracted is regulated.

18. The method according to claim 17, characterized in that Wherein from which station at the compressor section the compressed fluid flow is extracted is regulated based at least on a pressure requirement at the cooling system and an operating mode of the propulsion system.

19. The method according to claim 1, characterized in that The method comprises: The compressed fluid flow is provided to a heat load downstream of the turbine.

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