Thermal management system

Abstract

A gas turbine engine is provided. In one embodiment, a gas turbine engine includes a thermal management system having a thermal fluid component having a thermal fluid flow therethrough during operation of the gas turbine engine and a heat exchanger assembly including a core section including a plurality of heat exchange components; and a heat exchange manifold including a first directional pressure vessel in fluid communication with the thermal fluid component and a second directional pressure vessel extending from the first directional pressure vessel, the first directional pressure vessel and the second directional pressure vessel each extending in a reference plane, the second direction pressure vessel is in fluid communication with the first direction pressure vessel and is in fluid communication with at least one of the plurality of heat exchange members.

Description

Technical Field

[0001] The present disclosure relates to a thermal management system having a heat exchanger assembly, such as a thermal management system for a gas turbine engine. Background Art

[0002] A gas turbine engine typically includes a turbine and a rotor assembly. A gas turbine engine, such as a turbofan engine, may be used for aircraft propulsion. In the case of a turbofan engine, the rotor assembly may be configured as a fan assembly. A gas turbine engine typically includes a thermal management system to manage thermal loads during operation of the gas turbine engine. BRIEF DESCRIPTION OF THE DRAWINGS

[0003] A full and enabling disclosure of the present 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:

[0004] Figure 1 is a cross-sectional view of a gas turbine engine according to an exemplary aspect of the present disclosure.

[0005] Figure 2 is a perspective view of a thermal management system according to an exemplary embodiment of the present disclosure.

[0006] Figure 3 yes Figure 2 A cross-sectional view of an inlet heat exchange manifold of a heat exchanger assembly of a thermal management system.

[0007] Figure 4 It is along Figure 3 Line 4-4 observed in Figure 3 Cross-sectional view of the inlet heat exchange manifold of a heat exchanger assembly.

[0008] Figure 5 is a cross-sectional view of a heat exchange manifold according to another exemplary embodiment of the present disclosure.

[0009] Figure 6 is a schematic diagram of a heat exchange manifold of a heat exchanger assembly according to another exemplary embodiment of the present disclosure.

[0010] Figure 7 It is along Figure 6 The position between two adjacent discharge port extensions observed by line 7-7 Figure 6 Schematic cross-sectional view of an exemplary heat exchange manifold.

[0011] Figure 8 Includes and falls into Fig. 9 Table of corresponding values ​​for several heat exchangers within the depicted range.

[0012] Fig. 9A plot is provided of hydraulic diameter relationship (HDR) values ​​on the Y-axis and the air chamber to discharge port length ratio on the X-axis.

[0013] Fig.10 Provides includes and falls into Fig.11 Table of corresponding values ​​for several heat exchangers within the depicted range.

[0014] Fig.11 A plot is provided of the rib thickness relationship (RTR) values ​​on the Y-axis and the air chamber to exhaust port length ratio on the X-axis. DETAILED DESCRIPTION

[0015] Reference will now be made in detail to the present embodiments of the present disclosure, one or more examples of which are illustrated in the accompanying drawings. The detailed description uses numerical and letter references to refer to features in the drawings. Like or similar reference numbers in the drawings and description have been used to refer to like or similar parts of the present disclosure.

[0016] The word "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any implementation described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other implementations. In addition, unless expressly stated otherwise, all embodiments described herein should be considered exemplary.

[0017] The singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise.

[0018] The term "at least one" in a context such as "at least one of A, B, and C" means only A, only B, only C, or any combination of A, B, and C.

[0019] The term “turbomachine” refers to a machine that includes one or more compressors, a heat generating section (eg, a combustion section), and one or more turbines that together generate a torque output.

[0020] The term "gas turbine engine" refers to an engine having a turbine as all or part of its power source. Example gas turbine engines include turbofan engines, turboprop engines, turbojets, turboshaft engines, etc., as well as hybrid-electric versions of one or more of these engines.

[0021] The term "combustion section" refers to any heat addition system for a turbomachine. For example, the term combustion section may refer to a section that includes one or more of a deflagration combustion assembly, a rotating detonation combustion assembly, a pulse detonation combustion assembly, or other suitable heat addition assemblies. In certain example embodiments, the combustion section may include an annular combustor, a can combustor, a tubular combustor, a trapped vortex combustor (TVC), or other suitable combustion systems, or a combination thereof.

[0022] When used with reference to compressors, turbines, shaft or spool components, etc., the terms "low" and "high", or their respective comparatives (e.g., "lower" and "higher", where applicable), refer to relative speeds within the engine unless otherwise specified. For example, a "low turbine" or "low-speed turbine" defines a component that is configured to operate at a lower rotational speed (e.g., maximum allowable rotational speed) than a "high turbine" or "high-speed turbine" of the engine.

[0023] As used herein, "tertiary flow" refers to a non-primary air flow that can increase the energy of the fluid to produce a small portion of the total propulsion system thrust. The tertiary flow can typically receive inlet air (air from a ducted passage downstream of the primary fan) rather than free stream air (as the primary fan does). The pressure ratio of the tertiary flow can be higher than the pressure ratio of the primary propulsion flow (e.g., bypass or propeller-driven propulsion flow). Thrust can be generated through a dedicated nozzle, or by mixing the airflow through the tertiary flow with the primary propulsion flow or core air flow (e.g., into a common nozzle).

[0024] In certain exemplary embodiments, the operating temperature of the airflow through the third flow can be less than the maximum compressor discharge temperature of the engine, and more specifically, can be less than 350 degrees Fahrenheit (e.g., less than 300 degrees Fahrenheit, such as less than 250 degrees Fahrenheit, such as less than 200 degrees Fahrenheit, and at least the same as the ambient temperature). In certain exemplary embodiments, these operating temperatures can facilitate heat transfer to or from the airflow through the third flow and the separate fluid flows. Further, in certain exemplary embodiments, under takeoff conditions, or more specifically, when operating at rated takeoff power under sea level, static flight speed, 86 degrees Fahrenheit ambient temperature operating conditions, the airflow through the third flow can contribute less than 50% of the total engine thrust (and, for example, at least 2% of the total engine thrust).

[0025] Furthermore, in certain exemplary embodiments, various aspects of the airflow through the third stream (e.g., air flow, mixing, or exhaust characteristics), and thereby the above-described exemplary percentage contributions to total thrust, can be passively adjusted during engine operation, or purposefully modified through the use of engine control features (e.g., fuel flow, motor power, variable stators, variable inlet guide vanes, valves, variable exhaust geometry, or flow characteristics) to adjust or optimize overall system performance across a wide range of potential operating conditions.

[0026] 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 each component.

[0027] The term "adjacent" as used herein when referring to two similar components means that the components are only separated by different components.

[0028] As used herein, the term "monolithic" used to describe a structure means that the structure is formed integrally from a continuous material or group of materials without seams, connections, joints, etc. The monolithic structures described herein may be formed by additive manufacturing to have the structure, or alternatively by a casting process or other suitable method.

[0029] As used herein, the term "additive manufacturing" generally refers to a manufacturing technique that manufactures components in a layer-by-layer manner. An exemplary additive manufacturing machine may be configured to utilize any suitable additive manufacturing technique. The additive manufacturing machine may utilize additive manufacturing techniques including powder bed fusion (PBF) techniques, such as direct metal laser melting (DMLM) techniques, selective laser melting (SLM) techniques, directional metal laser sintering (DMLS) techniques, or selective laser sintering (SLS) techniques. In the exemplary PBF technique, thin layers of powdered material are sequentially applied to a build plane and then selectively melted or fused to each other in a layer-by-layer manner to form one or more three-dimensional objects. Additively manufactured objects are typically monolithic in nature and may have various integrated sub-components.

[0030] Additionally or alternatively, suitable additive manufacturing techniques may include, for example, fused deposition modeling (FDM) techniques, direct energy deposition (DED) techniques, laser engineered net shaping (LENS) techniques, laser net shaping manufacturing (LNSM) techniques, direct metal deposition (DMD) techniques, digital light processing (DLP) techniques, and other additive manufacturing techniques that utilize energy beams or other energy sources to solidify additive manufacturing materials (such as powder materials). In fact, any suitable additive manufacturing mode can be used for the subject matter currently disclosed.

[0031] Additive manufacturing techniques can generally be described as making objects by building objects point by point, line by line, or layer by layer, typically in a vertical direction. Other methods of making are also contemplated and within the scope of the present disclosure. For example, although the discussion herein relates to adding materials to form successive layers, the subject matter of the present disclosure can be practiced with any additive manufacturing technique or other manufacturing technique, including layer-additive, layer-subtractive, or hybrid processes.

[0032] Typically, a turbofan engine includes a fan and a turbine, wherein the turbine rotates the fan to generate thrust. The turbine includes a compressor section, a combustion section, a turbine section, and an exhaust section, and defines a working gas flow path therethrough.

[0033] Within a turbofan engine, thermal management may be important to ensure that the turbofan engine operates as desired without allowing certain components to exceed temperature thresholds. For example, a thermal management system for a turbofan engine may operate during operation of the turbofan engine to reduce the temperature of lubricating oil (e.g., lubricating oil used for various bearings and gears within the turbofan engine), cooled cooling air, electronic equipment systems, etc. The thermal management system may utilize thermal fluids and heat exchangers to transfer heat from a heat source to a heat sink.

[0034] Generally, it is desirable to operate thermal fluids and heat exchangers at high pressures to enhance the heat transfer performance of the thermal fluids and heat exchangers. However, in order to operate at high pressures, heat exchangers traditionally require pressure vessels with substantial stringers between outflow channels to support the loads created by the high pressure of the thermal fluid. Such a configuration may result in an undesirably large pressure loss / drop between the pressure vessel and the outflow channels, as well as poor distribution of the thermal fluid due to reduced access to the pressure vessel caused by the substantial stringers. Previous thinking has been to increase the size of the pressure vessel to allow access to the high pressure thermal fluid from the additional outflow channels.

[0035] However, the inventors of the present disclosure have discovered that such a design process may result in an undesirably heavy and large pressure vessel, which may cause undesirable blockage of the gas flow through the working gas flow path when the heat exchanger is used in the working gas flow path of a turbofan engine. The inventors of the present disclosure have set out to design a heat exchanger for a thermal management system of a turbofan engine or other gas turbine engine to address the above-mentioned problems.

[0036] In particular, as will be explained in more detail with reference to the exemplary embodiments described herein, the inventors of the present disclosure have discovered a heat exchanger assembly having a core section and a heat exchange manifold. The core section includes a plurality of heat exchange members, and the heat exchange manifold includes a first direction pressure vessel (or more specifically, an air chamber extension) and a second direction pressure vessel (or more specifically, an exhaust port extension). The air chamber extension is in fluid communication with the thermal fluid member of the turbofan engine, and the exhaust port extension is in fluid communication with the air chamber extension and at least one of the plurality of heat exchange members of the core section. In certain embodiments, the heat exchanger assembly may include a plurality of air chamber extensions and a plurality of exhaust port extensions, each air chamber extension being in fluid communication with the thermal fluid member in parallel (or in serial fluid communication with the thermal fluid member, or both), each exhaust port extension being in fluid communication with one or more air chamber extensions and in fluid communication with at least one of the plurality of heat exchange members.

[0037] As part of designing a heat exchanger, such as the heat exchanger briefly described above, the inventors of the present disclosure unexpectedly discovered that by including multiple pressure vessels arranged as a network of extensions (e.g., plenum extensions and exhaust port extensions), rather than increasing the size of a single pressure vessel, a heat exchanger having a manifold can be provided that reduces obstruction to the working gas flow path of a turbofan engine and reduces weight while accommodating the desired high pressures and providing improved thermal fluid distribution for the core section.

[0038] In particular, the inventors discovered in the course of designing several heat exchangers (including the heat exchangers and engines detailed and described herein) to be used with several engine architectures of varying thrust classes and mission requirements that a relationship exists between the plenum hydraulic diameter ratio; the exhaust port hydraulic diameter ratio; and the plenum to exhaust port length ratio, such that a heat exchanger including one or more of the exemplary aspects that take into account such a relationship can produce a net benefit to the overall engine design.

[0039] Additionally, in at least certain exemplary embodiments, the inventors of the present disclosure have discovered that by including one or more ribs extending between adjacent discharge port extensions, between adjacent plenum extensions, or between adjacent discharge port extensions and between adjacent plenum extensions, an overall reduction in the size of the heat exchange manifold can be provided by providing additional strength to the component. Furthermore, by limiting the size (or thickness) of the ribs, the ribs can be included without providing excessive obstruction to the flow of hot fluid through the plenum extensions and / or the discharge port extensions. With such a configuration, the inventors of the present disclosure have further discovered that there is a relationship between the average discharge port hydraulic diameter and the rib thickness; and the average plenum hydraulic diameter and the rib thickness, such that a heat exchanger including one or more of the exemplary aspects in accordance with consideration of such a relationship can produce a net benefit to the overall engine design.

[0040] As previously mentioned, previous thinking has been to include a single large volume pressure vessel to accommodate the desired thermal fluid pressure and distribution levels.

[0041] In order to obtain an improved turbofan engine capable of transferring relatively large amounts of heat from a high-pressure hot fluid to a heat sink (e.g., the working gas passage of a turbofan engine), the inventors, during the design of several different types of heat exchangers and gas turbine engines (including the heat exchangers and gas turbine engines described below), designed a gas turbine engine having a heat exchanger with various air chamber hydraulic diameter ratios, discharge port hydraulic diameter ratios, air chamber to discharge port length ratios, average discharge port hydraulic diameter to rib thickness, and average air chamber hydraulic diameter to rib thickness; checked the operability and heat dissipation characteristics of the designed gas turbine engine and heat exchanger; redesigned the gas turbine engine and heat exchanger to change the parameters based on the impact on other aspects of the gas turbine engine; rechecked the operability and heat dissipation characteristics of the redesigned gas turbine engine and heat exchanger; and so on.

[0042] Reference now Figure 1 , a schematic cross-sectional view of a gas turbine engine or “engine 100” is provided in accordance with an exemplary embodiment of the present disclosure. In particular, Figure 1 A turbofan engine having a rotor assembly having a single stage of non-ducted rotor blades is provided. In this manner, the rotor assembly may be referred to herein as a "non-ducted fan," or the entire engine 100 may be referred to as a "non-ducted turbofan engine." Additionally, Figure 1 The engine 100 includes a third flow path extending from the compressor section to the rotor assembly on the turbine, as will be explained in more detail below.

[0043] For reference, the engine 100 defines an axial direction A, a radial direction R, and a circumferential direction C. Further, the engine 100 defines an axial centerline or longitudinal axis 112 extending along the axial direction A. Generally, the axial direction A extends parallel to the longitudinal axis 112, the radial direction R extends outwardly from the longitudinal axis 112 and inwardly to the longitudinal axis 112 in a direction perpendicular to the axial direction A, and the circumferential direction extends three hundred sixty degrees (360°) around the longitudinal axis 112. The engine 100 extends, for example, along the axial direction A between a front end 114 and a rear end 116.

[0044] The engine 100 includes a turbine 120 and a rotor assembly (also referred to as a fan section 150) positioned upstream thereof. Generally, the turbine 120 includes a compressor section, a combustion section, a turbine section, and an exhaust section in a serial flow order. In particular, as shown in FIG. Figure 1As shown, the turbine 120 includes a core shroud 122 that defines an annular core inlet 124. The core shroud 122 also at least partially surrounds a low-pressure system and a high-pressure system. For example, the core shroud 122 shown at least partially surrounds and supports a boost or low-pressure ("LP") compressor 126 for pressurizing air entering the turbine 120 through the core inlet 124. A high-pressure ("HP") multi-stage axial compressor 128 receives the pressurized air from the LP compressor 126 and further increases the pressure of the air. The pressurized air flow flows downstream to the combustor 130 of the combustion section, in which the fuel is injected into the pressurized air flow and ignited to increase the temperature and energy level of the pressurized air.

[0045] It should be understood that, as used herein, the terms "high / low speed" and "high / low pressure" are used interchangeably with respect to high pressure / high speed systems and low pressure / low speed systems. In addition, it should be understood that the terms "high" and "low" are used in the same context to distinguish between the two systems and are not meant to imply any absolute speed and / or pressure values.

[0046] The high-energy combustion products flow downstream from the combustor 130 to the high-pressure turbine 132. The high-pressure turbine 132 drives the high-pressure compressor 128 via a high-pressure shaft 136. In this regard, the high-pressure turbine 132 is drivingly coupled to the high-pressure compressor 128. The high-energy combustion products then flow to the low-pressure turbine 134. The low-pressure turbine 134 drives the low-pressure compressor 126 and components of the fan section 150 via a low-pressure shaft 138. In this regard, the low-pressure turbine 134 is drivingly coupled to components of the low-pressure compressor 126 and the fan section 150. In this example embodiment, the low-pressure shaft 138 is coaxial with the high-pressure shaft 136. After driving each of the turbines 132, 134, the combustion products exit the turbine 120 through the turbine exhaust nozzle 140.

[0047] Thus, the turbine 120 defines a working gas flow path or core duct 142 extending between the core inlet 124 and the turbine exhaust nozzle 140. The core duct 142 is an annular duct positioned generally inwardly of the core shroud 122 in the radial direction R. The core duct 142 (e.g., the working gas flow path through the turbine 120) may be referred to as a secondary flow.

[0048] Fan section 150 includes a fan 152, which in this example embodiment is a primary fan. Figure 1 In the illustrated embodiment, the fan 152 is an open rotor or non-ducted fan 152. In this manner, the engine 100 may be referred to as an open rotor engine.

[0049] As depicted, fan 152 includes an array of fan blades 154 ( Figure 1Only one is shown in FIG. 1 ). Fan blades 154 are rotatable, for example, about longitudinal axis 112. As described above, fan 152 is drivingly coupled to low-pressure turbine 134 via low-pressure shaft 138. Figure 1 In the illustrated embodiment, the fan 152 is coupled to the low pressure shaft 138 via a reduction gearbox 155 , for example, in an indirect drive or gear drive configuration.

[0050] In addition, the array of fan blades 154 can be arranged equally spaced around the longitudinal axis 112. Each fan blade 154 has a root and a tip and a span defined therebetween. Each fan blade 154 defines a central blade axis 156. For this embodiment, each fan blade 154 of the fan 152 can rotate around its central blade axis 156, for example in unison with each other. One or more actuators 158 are provided to facilitate such rotation and can therefore be used to change the pitch of the fan blades 154 around their respective central blade axes 156.

[0051] The fan section 150 also includes a fan guide vane array 160 including fan guide vanes 162 ( Figure 1 For this embodiment, fan guide vanes 162 are non-rotatable about longitudinal axis 112. Each fan guide vane 162 has a root and a tip, and a span defined therebetween. Fan guide vanes 162 may be configured as follows: Figure 1 It is shown unshielded, or alternatively, may be shielded, for example, by an annular shroud spaced outwardly in the radial direction R from the tip of the fan guide vanes 162 or attached to the fan guide vanes 162 .

[0052] Each fan guide vane 162 defines a central blade axis 164. For this embodiment, each fan guide vane 162 of the fan guide vane array 160 can rotate about its respective central blade axis 164, for example in unison with each other. One or more actuators 166 are provided to facilitate such rotation, and thus can be used to change the pitch of the fan guide vanes 162 about their respective central blade axis 164. However, in other embodiments, each fan guide vane 162 can be fixed or unable to pitch about its central blade axis 164. The fan guide vanes 162 are mounted to the fan housing 170.

[0053] like Figure 1As shown, in addition to the non-ducted fan 152, a ducted fan 184 is also included behind the fan 152, so that the engine 100 includes ducted and non-ducted fans, both of which are used to generate thrust by the movement of air without passing through at least a portion of the turbine 120 (e.g., for the depicted embodiment, without passing through the high-pressure compressor 128 and the combustion section). The ducted fan 184 can rotate around the same axis as the fan blades 154 (e.g., the longitudinal axis 112). For the depicted embodiment, the ducted fan 184 is driven by the low-pressure turbine 134 (e.g., connected to the low-pressure shaft 138). In the described embodiment, as described above, the fan 152 can be referred to as a primary fan, and the ducted fan 184 can be referred to as a secondary fan. It should be understood that these terms "primary" and "secondary" are convenient terms and do not mean any particular importance, rights, etc.

[0054] Ducted fan 184 includes a plurality of fan blades arranged in a single stage (in Figure 1 112 ), so that the ducted fan 184 can be referred to as a single-stage fan. The fan blades of the ducted fan 184 can be arranged at equal intervals around the longitudinal axis 112. Each blade of the ducted fan 184 has a root and a tip and a span defined therebetween.

[0055] The fan cover 170 annularly surrounds at least a portion of the core cover 122, and is generally positioned outside at least a portion of the core cover 122 in the radial direction R. In particular, a downstream section of the fan cover 170 extends on the front portion of the core cover 122 to define a fan duct flow path, or simply referred to as a fan duct 172. According to this embodiment, the fan flow path or fan duct 172 may be understood to form at least a portion of the third flow of the engine 100 (e.g., another working gas flow path of the engine 100).

[0056] Incoming air may enter through fan duct 172 through fan duct inlet 176 and may be discharged through fan exhaust nozzle 178 to generate propulsive thrust. Fan duct 172 is an annular duct positioned generally outside core duct 142 in radial direction R. Fan cowl 170 and core cowl 122 are connected together and are supported by a plurality of substantially radially extending, circumferentially spaced stationary struts 174 ( Figure 1The fan duct 172 and the core duct 142 may be supported by the fan duct 170 and the core duct 142. The fan duct 172 and the core duct 142 may be supported by the fan duct 170 and the core duct 122. The fan duct 172 and the core duct 142 may be supported by the fan duct 170 and the core duct 122. The fan duct 172 and the core duct 142 may be supported by the fan duct 170 and the core duct 14 ...

[0057] The engine 100 also defines or includes an inlet duct 180. The inlet duct 180 extends between the engine inlet 182 and the core inlet 124 / fan duct inlet 176. The engine inlet 182 is generally defined at the front end of the fan cover 170 and is positioned between the fan 152 and the fan guide vane array 160 along the axial direction A. The inlet duct 180 is an annular duct positioned inside the fan cover 170 along the radial direction R. The air flowing downstream along the inlet duct 180 is divided into the core duct 142 and the fan duct 172 by the fan duct splitter or leading edge 144 of the core cover 122, not necessarily uniformly. In the depicted embodiment, the inlet duct 180 is wider than the core duct 142 along the radial direction R. The inlet duct 180 is also wider than the fan duct 172 along the radial direction R.

[0058] It is worth noting that for the depicted embodiment, engine 100 includes one or more features to increase the third flow thrust Fn 3S (e.g., thrust generated by airflow through fan duct 172 exiting through fan exhaust nozzle 178, which airflow is generated at least in part by ducted fan 184). In particular, engine 100 also includes an array of inlet guide vanes 186 positioned in inlet duct 180, upstream of ducted fan 184 and downstream of engine inlet 182. The array of inlet guide vanes 186 is arranged around longitudinal axis 112. For this embodiment, inlet guide vanes 186 are not rotatable around longitudinal axis 112. Each inlet guide vane 186 defines a central blade axis (not marked for clarity) and can rotate around its respective central blade axis, for example, in unison with each other. In this way, inlet guide vanes 186 can be considered as variable geometry components. One or more actuators 188 are provided to facilitate such rotation, and can therefore be used to change the pitch of inlet guide vanes 186 around their respective central blade axes. However, in other embodiments, each inlet guide vane 186 can be fixed or cannot be pitched around its central blade axis.

[0059] Additionally, downstream of ducted fan 184 and upstream of fan duct inlet 176, engine 100 includes an array of outlet guide vanes 190. As with the array of inlet guide vanes 186, the array of outlet guide vanes 190 is not rotatable about longitudinal axis 112. However, for the depicted embodiment, unlike the array of inlet guide vanes 186, the array of outlet guide vanes 190 is configured as fixed pitch outlet guide vanes.

[0060] Furthermore, it should be understood that for the depicted embodiment, the fan exhaust nozzle 178 of the fan duct 172 is also configured as a variable geometry exhaust nozzle. In this manner, the engine 100 includes one or more actuators 192 for regulating the variable geometry exhaust nozzle. For example, the variable geometry exhaust nozzle may be configured to vary the total cross-sectional area (e.g., the area of ​​the nozzle in a plane perpendicular to the longitudinal axis 112) to regulate the amount of thrust generated based on one or more engine operating conditions (e.g., temperature, pressure, mass flow rate, etc. of the airflow through the fan duct 172). Fixed geometry exhaust nozzles may also be employed.

[0061] The combination of the array of inlet guide vanes 186 located upstream of ducted fan 184, the array of outlet guide vanes 190 located downstream of ducted fan 184, and fan exhaust nozzle 178 may result in a third flow thrust Fn during one or more engine operating conditions. 3S Furthermore, by introducing variability in the geometry of the inlet guide vanes 186 and the fan exhaust nozzle 178, the engine 100 may be capable of operating over a relatively wide range of engine operating conditions, including takeoff and climb (which typically require a maximum total engine thrust Fn Total ) and cruise (usually requires a smaller amount of total engine thrust Fn Total )) Generate more efficient third flow thrust Fn 3S .

[0062] In addition, still refer to Figure 1 In an exemplary embodiment, the air passing through the fan duct 172 may be relatively cooler (e.g., lower in temperature) than one or more fluids used in the turbine 120. In this manner, one or more heat exchangers 198 are positioned in thermal communication with the fan duct 172. For example, one or more heat exchangers 198 are disposed within the fan duct 172 and are used to cool one or more fluids from the core engine, wherein the air passing through the fan duct 172 serves as a resource for removing heat from the fluid (e.g., compressor bleed air, oil, or fuel).

[0063] Although not depicted, heat exchanger 198 may be an annular heat exchanger extending substantially 360 degrees (e.g., at least 300 degrees, such as at least 330 degrees) in fan duct 172. In this manner, heat exchanger 198 may effectively utilize air passing through fan duct 172 to cool one or more systems of engine 100 (e.g., lube oil system, compressor bleed air, electrical components, etc.). Heat exchanger 198 uses air passing through fan duct 172 as a heat sink and correspondingly increases the temperature of the air downstream of heat exchanger 198 and exiting fan exhaust nozzle 178.

[0064] However, it should be understood that Figure 1 The exemplary gas turbine engine 100 depicted in FIG. 1 is for example only. In other exemplary embodiments, the gas turbine engine 100 may have any other suitable configuration. For example, in other exemplary embodiments, the gas turbine engine 100 may be configured as a ducted gas turbine engine (e.g., including a nacelle surrounding the fan 152), may be a direct drive gas turbine engine (e.g., driving the fan 152 without using a reduction gearbox 155), etc. In addition, although the heat exchanger 198 is depicted as being positioned in the fan duct 172, in other exemplary embodiments, the gas turbine engine 100 may additionally or alternatively include a heat exchanger 198' in the exhaust nozzle 140 or at other suitable locations.

[0065] Reference now Figure 2 , a thermal management system 200 is provided according to an exemplary embodiment of the present disclosure. The exemplary thermal management system 200 generally includes a thermal fluid component 202, a heat exchanger assembly 204, and, for the illustrated embodiment, a piping system 206. Although Figure 2 In the embodiment described above, the thermal fluid component 202 is described as part of the thermal management system 200, but in other embodiments, the thermal fluid component 202 can be configured as part of the gas turbine engine in which the thermal management system 200 is installed.

[0066] For example, in at least some exemplary embodiments, the thermal management system 200 may incorporate the thermal management system 200 described above with reference to Figure 11. The exemplary engine 100 of the embodiment of the present invention is shown in FIG. 1. In such exemplary aspects, the heat exchanger assembly 204 can be constructed in a manner similar to the exemplary heat exchanger 198 and positioned in a working gas flow path similar to the fan duct 172 of the engine 100. In addition, for such exemplary aspects, the thermal fluid component 202 can be one or more of a lubricating oil system, a cooled cooling air system, an electronic equipment cooling system, etc. The thermal fluid component 202 can circulate a thermal fluid from such a system (e.g., lubricating oil from a lubricating oil system) through the piping system 206 to thermally connect the thermal fluid component 202 to the heat exchanger assembly 204. Alternatively, the thermal fluid component 202 can be an intermediate heat exchanger configured to be thermally connected to such a system and can circulate an intermediate thermal fluid through the piping system 206.

[0067] Figure 2 The heat exchanger assembly 204 depicted in FIG. 2 generally includes a core section 208 having a plurality of heat exchange components 210 and a heat exchange manifold 212 in fluid communication with the thermal fluid component 202. In particular, for the illustrated embodiment, the heat exchange manifold 212 is an inlet heat exchange manifold 212A configured to receive a thermal fluid flow from the thermal fluid component 202, and the heat exchanger assembly 204 also includes an outlet heat exchange manifold 212B positioned relative to the core section 208 from the inlet heat exchange manifold 212A and configured to provide a thermal fluid flow back to the thermal fluid component 202.

[0068] It is worth noting that in the illustrated embodiment, the inlet heat exchange manifold 212A extends in a first reference plane defined by the axial direction A and the radial direction R of the thermal management system 200 (when the thermal management system 200 is installed in such a gas turbine engine, the axial direction A and the radial direction R of the thermal management system 200 may be the same as Figure 1 The plurality of heat exchange members 210 extend perpendicular to the first reference plane. More specifically, it should be understood that the thermal management system 200 further defines a circumferential direction C (which may also be aligned with the circumferential direction C when the thermal management system 200 is installed in such a gas turbine engine). Figure 1 The heat exchange members 210 are aligned in the circumferential direction C of the exemplary engine 100 of the present invention, and the plurality of heat exchange members 210 extend from the inlet heat exchange manifold 212A to the outlet heat exchange manifold 212B in the circumferential direction C. As will be further understood, with such a configuration, when the thermal management system 200 is installed in a gas turbine engine, the plurality of heat exchange members 210 may more specifically extend through the annular flow path of the gas turbine engine in the circumferential direction C (e.g., extending through the annular flow path of the gas turbine engine in the circumferential direction C). Figure 1 172 in the embodiment of the present invention).

[0069] As will be explained in more detail below, the hot fluid may generally flow into the inlet heat exchange manifold 212A, where the hot fluid is directed into and through the plurality of heat exchange components 210 of the core section 208. The heat exchange components 210 may be positioned within an air flow duct of the gas turbine engine, such as within an annular flow path of the gas turbine engine, such that relatively cool air passes over and around the plurality of heat exchange components 210, thereby reducing the temperature of the hot fluid directed through the heat exchange components 210. The hot fluid is then received by the outlet heat exchange manifold 212B.

[0070] In certain exemplary embodiments, the thermal management system 200 may include a plurality of heat exchanger assemblies 204 arranged in a working gas flow path of a gas turbine engine. The plurality of heat exchanger assemblies 204 may be arranged in series (where Figure 2 The outlet heat exchange manifold 212B depicted in FIG. 1 is fluidly connected to the inlet heat exchange manifold of the second heat exchanger assembly; not shown), may be arranged in parallel, or may be fluidly coupled to various hot fluid components 202 of the gas turbine engine.

[0071] Reference now Figure 3 , depicting Figure 2 FIG. 2 is a cross-sectional view of an inlet heat exchange manifold 212A of a heat exchanger assembly 204 of FIG. As will be appreciated, the inlet heat exchange manifold 212A includes a first direction pressure vessel in fluid communication with the thermal fluid member 202 and a second direction pressure vessel extending from the first direction pressure vessel. The first direction pressure vessel and the second direction pressure vessel each extend within a first reference plane defined by the thermal management system 200, which is Figure 3 In addition, it should be understood that the second direction pressure vessel is in fluid communication with the first direction pressure vessel and is in fluid communication with at least one of the plurality of heat exchange components 210 of the core section 208 of the heat exchanger assembly 204 .

[0072] In particular, for the illustrated embodiment, the first directional pressure vessel is the plenum extension 214 and the second directional pressure vessel is the vent extension 216 .

[0073] Furthermore, for the illustrated embodiment, the plenum extension 214 is one of a plurality of plenum extensions 214 of the inlet heat exchange manifold 212A. Each of the plurality of plenum extensions 214 is in parallel fluid communication with the hot fluid component 202. In particular, for the illustrated embodiment, the inlet heat exchange manifold 212A includes two plenum extensions 214, and each of the plenum extensions 214 extends generally along the radial direction R (i.e., within 30 degrees of the radial direction R, such as within 15 degrees of the radial direction R).

[0074] Similarly, for the illustrated embodiment, the discharge port extension 216 is one of a plurality of discharge port extensions 216 of the inlet heat exchange manifold 212A. Each of the plurality of discharge port extensions 216 extends from one of the plurality of plenum extensions 214 in the first reference plane. In particular, each of the plurality of discharge port extensions 216 is in fluid communication with at least one of the plenum extensions 214, and further in fluid communication with at least one of the heat exchange components 210 of the core section 208 of the heat exchanger assembly 204. More specifically, it should be understood that in the illustrated embodiment, each of the discharge port extensions 216 defines a plurality of apertures 218 longitudinally arranged along the corresponding discharge port extension 216. Each of the plurality of apertures 218 is fluidly coupled to the heat exchange component 210 of the core section 208 of the heat exchanger assembly 204. The apertures 218 may have any suitable geometry to facilitate transition to the heat exchange component 210 (e.g., an elongated slot, a circular opening, etc.).

[0075] It should also be understood that for the exemplary embodiment described, the plurality of sump extensions 216 are further in fluid communication with each other. Figure 4 , provides along Figure 3 Line 4-4 observed in Figure 3 FIG. 2 is a cross-sectional view of the inlet heat exchange manifold 212A of the heat exchanger assembly 204, and it should be understood that the inlet heat exchange manifold 212A defines a plurality of fluid connection channels 220 extending between adjacent discharge port extensions 216. In addition, the inlet heat exchange manifold 212A includes a plurality of ribs 222 extending between adjacent discharge port extensions 216 in the plurality of discharge port extensions 216. The plurality of ribs 222 define a plurality of fluid connection channels 220.

[0076] Special return reference Figure 3 , and as described above, the inlet heat exchange manifold 212A includes two plenum extensions 214. The inlet heat exchange manifold 212A also includes five discharge port extensions 216. However, it should be understood that in other exemplary embodiments, the inlet heat exchange manifold 212A may have other suitable configurations. For example, in other exemplary embodiments, the inlet heat exchange manifold 212A may include two to twenty (20) discharge port extensions 216, such as three to fifteen (15) discharge port extensions 216, such as four to ten (10) discharge port extensions 216. In addition, for example, in at least some exemplary embodiments, the inlet heat exchange manifold 212A may include one to eight plenum extensions 214, such as two to five plenum extensions 214.

[0077] It will be further appreciated that the exemplary inlet heat exchange manifold 212A also includes a connector extension 224. The connector extension 224 extends between each of the plurality of discharge port extensions 216 and fluidly connects each of the plurality of discharge port extensions 216 at an end opposite the one or more plenum extensions 214.

[0078] As can be appreciated from the above description, the inlet heat exchange manifold 212A generally comprises a distributed network of fluid extensions / pressure vessels that can provide the desired high-pressure hot fluid flow in a relatively evenly distributed manner to the multiple heat exchange components 210 of the core section 208 of the heat exchanger assembly 204. This configuration can more specifically provide an inlet heat exchange manifold 212 having a distributed hot fluid delivery network that can provide high-pressure hot fluid to the multiple heat exchange components 210 of the core section 208 of the heat exchanger assembly 204 in an evenly distributed manner.

[0079] In particular, use of such a distributed network can allow for the provision of thermal fluid at elevated pressures while minimizing pressure losses across the fluid network. For example, by including a plurality of plenum extensions fluidly connected to each other and to a plurality of drain port extensions, the plenum extensions can have a relatively small hydraulic diameter, which can reduce the strength of the plenum extensions required to accommodate a thermal fluid at a given pressure. Additionally, including a plurality of drain port extensions fluidly connected to each other, and having a plurality of orifices arranged longitudinally along the drain port extensions, a smaller number of drain port extensions may be required to fluidly couple to the plenum extensions, thereby reducing blockage and pressure losses of the thermal fluid during operation.

[0080] In this manner, it should be understood that the inlet heat exchange manifold 212A described above may be referred to as a high pressure thermal fluid manifold. For example, during operation of a gas turbine engine including the thermal management system 200 described above, the plenum extension 214 of the inlet heat exchange manifold 212A may be configured to receive a thermal fluid at a pressure between 200 pounds per square inch (psi) and 3000 psi (such as greater than 300 psi, such as greater than 500 psi, such as greater than 1000 psi).

[0081] Furthermore, it should be appreciated that the inlet heat exchange manifold 212A depicted and described above is constructed as a unitary component, which may reduce the potential for leaks and other failure points, and provide the geometry described herein, which may be necessary to contain relatively high pressure thermal fluids during operation of the thermal management system 200. For example, in certain exemplary embodiments, the inlet heat exchange manifold 212A may be formed by additive manufacturing.

[0082] It will be further appreciated that the inlet heat exchange manifold 212A described above may provide a more compact heat exchange manifold 212, thereby allowing the heat exchange manifold 212 to occupy a smaller circumferential space footprint when incorporated into a gas turbine engine. For example, in certain exemplary embodiments, the heat exchanger assembly 204 may be positioned within the annular flow path 226 of the gas turbine engine (see Figure 4 ; see also e.g. Figure 1 For example, the heat exchanger assembly 204 may be incorporated into a gas turbine engine having an outer peripheral reference line 228 along a radial direction R at an axial position along the axial direction A and an inner peripheral reference line 230 along the radial direction R at an axial position ( Figure 3 , see also Figure 2 ). The outer peripheral reference line 228 may correspond to the radially outer boundary of the annular flow path 226, and the inner peripheral reference line 230 may correspond to the radially inner boundary of the annular flow path 226. The inlet heat exchange manifold 212A may be at least partially positioned between the outer peripheral reference line 228 and the inner peripheral reference line 230 (see, e.g., Figure 2 ).

[0083] In addition, refer again Figure 4 , the gas turbine engine in which the thermal management system 200 is positioned may include, for example, struts 232 extending through the annular flow path 226 at the above-mentioned axial locations. Figure 4 2, it should be appreciated that the strut 232 may include an aerodynamic surface 234 exposed to the annular flow path 226, and the heat exchange manifold 212 may be at least partially positioned inboard of the aerodynamic surface 234 of the strut 232. In this manner, the heat exchanger assembly 204 may reduce airflow obstruction caused by incorporating the heat exchanger assembly 202 within a gas turbine engine.

[0084] It should be understood that although the above description relates to the inlet heat exchange manifold 212A, in certain exemplary embodiments of the present disclosure, the outlet heat exchange manifold 212 may be configured in substantially the same manner as the above-described inlet heat exchange manifold 212A.

[0085] Furthermore, it should be understood that the exemplary heat exchange manifold 212 described above is provided as an example only. In other exemplary embodiments, a heat exchanger assembly 204 having a heat exchange manifold 212 configured in any other suitable manner may be provided. For example, although the heat exchanger assembly 204 described above is described as having a core section 208 extending through the working gas flow path of the engine (e.g., a third flow, a turbine flow path, a bypass flow path, etc.), in other exemplary embodiments, the heat exchanger assembly 204 may not have a core section 208 extending through the working gas flow path of the engine. For example, in certain exemplary embodiments, the heat exchanger assembly 204 may be positioned in an under-hood position or other engine mounting position outside the flow path of the engine.

[0086] For example, now refer to Figure 5 , a heat exchange manifold 212 according to another exemplary embodiment of the present disclosure is provided. Figure 5 The example heat exchange manifold may be constructed in substantially the same manner as the example heat exchange manifold 212 described above.

[0087] For example, Figure 5 The exemplary heat exchange manifold 212 generally includes a plurality of plenum extensions 214 in fluid communication with the hot fluid component 202, and a plurality of exhaust port extensions 216 extending from the plurality of plenum extensions 214. The plurality of plenum extensions 214 and the plurality of exhaust port extensions 216 each extend within a reference plane. In addition, the plurality of exhaust port extensions 216 each are in fluid communication with at least one of the plurality of heat exchange components (not depicted; extending vertically from the reference plane within the housing 236 of the heat exchanger assembly 204).

[0088] However, for the described embodiments, the described exemplary heat exchange manifold 212 is configured as a bidirectional heat exchange manifold 212. In particular, the plurality of plenum extensions 214 include a plurality of inlet plenum extensions 214A and a plurality of outlet plenum extensions 214B. Similarly, the plurality of discharge port extensions 216 include a plurality of inlet discharge port extensions 216A extending from the plurality of inlet plenum extensions 214A, and a plurality of outlet discharge port extensions 216B extending from the plurality of outlet plenum extensions 214B. During operation, a hot fluid flow may be received by the plurality of inlet plenum extensions 214A and directed to the plurality of inlet discharge port extensions 216A. The plurality of inlet discharge port extensions 216A may provide the hot fluid to a plurality of heat exchange members (not shown; positioned in the housing 236), which may exchange heat with the radiator fluid flow and return the hot fluid to the plurality of outlet discharge port extensions 216B. The plurality of outlet exhaust extensions 216B may in turn provide thermal fluid to the plurality of outlet plenum extensions 214B and back to the thermal fluid component 202 .

[0089] Furthermore, in yet other exemplary embodiments, Figure 5 The heat exchange manifold 212 may be an inlet heat exchange manifold, and the heat exchanger assembly 204 may further include an outlet heat exchange manifold positioned opposite the inlet heat exchange manifold relative to the housing 236. In such a configuration, Figure 5 The plenum extension and exhaust port extension labeled 214A, 216A in the figure may correspond to the inlet plenum extension and the inlet exhaust port extension of the first thermal fluid, and Figure 5 The plenum extension and the exhaust port extension labeled 214B, 216B in FIG. 5 may correspond to the inlet plenum extension and the inlet exhaust port extension of the second thermal fluid. The first thermal fluid may be a hot fluid, and the second thermal fluid may be a cold fluid.

[0090] Additionally, in other exemplary embodiments, the heat exchanger assembly 204 may be operated in a counter-flow configuration, in which case, Figure 5 The plenum extension and exhaust port extension labeled 214A, 216A in the figure may correspond to the inlet plenum extension and the inlet exhaust port extension of the first thermal fluid, and Figure 5 The plenum extensions and exhaust port extensions labeled 214B, 216B in FIG. 2 may correspond to the outlet plenum extension and outlet exhaust port extension of the second thermal fluid.

[0091] In addition, in other exemplary embodiments, the heat exchanger assembly 204 of the present disclosure can be used in fields other than gas turbine engines. For example, in other exemplary aspects of the present disclosure, the heat exchanger assembly 204 according to one or more exemplary aspects described herein can be used with an internal combustion engine, or other machines or systems that need to transfer heat to / from a high-pressure thermal fluid.

[0092] Reference now Figure 6 , a schematic diagram of a heat exchange manifold 212 of a heat exchanger assembly 204 according to another exemplary embodiment of the present disclosure is provided. Figure 6 The exemplary heat exchange manifold 212 of may be configured in a similar manner as one or more of the exemplary heat exchange manifolds 212 described herein.

[0093] For example, Figure 6 The heat exchange manifold 212 includes a plurality of plenum extensions 214 and a plurality of discharge port extensions 216. Additionally, at least two of the plurality of discharge port extensions 216 are fluidly connected to one another and include a plurality of ribs 222 extending therebetween. Additionally, for the depicted embodiment, the plurality of plenum extensions 214 are fluidly connected to one another via a plurality of fluid connection channels 220 and include at least one rib 222 extending therebetween.

[0094] If from Figure 6 As can be understood from this schematic diagram, each of the plurality of air chamber extensions 214 extends between an air chamber extension inlet 240 and an air chamber extension outlet 242 and defines an air chamber extension length L from the air chamber extension inlet 240 to the air chamber extension outlet 242. Plenum Similarly, each of the plurality of stomal extensions 216 extends from a stomal extension inlet 244 to a stomal extension outlet 246 and defines a stomal extension length L from the stomal extension inlet 244 to the stomal extension outlet 246 . Offtake .

[0095] As used herein, the plenum extension inlet 240 is located at the location where the plenum extension 214 connects to the duct system 206 of the thermal management system 200, at the most upstream location along the plenum extension 214 (i.e., in the case of the inlet heat exchange manifold 212A; opposite in the case of the outlet heat exchange manifold 212B). Where multiple plenum extensions 214 are provided, the plenum extension inlet 240 of each plenum extension 214 is located at the location where the plenum extension connects to the duct system 206, or at locations where the plenum extensions 214 are separated from each other (see, e.g., Figure 5 As used herein, the plenum extension outlet 242 is located at the location where the plenum extension 214 terminates.

[0096] The air chamber extension length L of each air chamber extension 214 Plenum is the length along the centerline 248 of the corresponding plenum extension 214 from the corresponding plenum extension inlet 240 to the corresponding plenum extension outlet 242 .

[0097] As used herein, the sump extension inlet 244 is located where the sump extension 216 meets the plenum extension 214, while the sump extension outlet 246 is located where the sump extension 216 contacts the connector extension at the end opposite the plenum extension 214 (see Figure 3 224 in the connector extension), or, if no connector extension is provided, at the location where the discharge port extension 216 is last fluidly connected to an adjacent discharge port extension 216 or one or more heat exchange components 210 through the orifice 218.

[0098] The sprue extension length L of each sprue extension 216 Offtake is the length along the centerline 250 of the corresponding stomal extension 216 from the corresponding stomal extension inlet 244 to the corresponding stomal extension outlet 246 .

[0099] Reference now Figure 7 , provides along Figure 6 Line 7-7 in the observation Figure 6Schematic cross-sectional view between two adjacent discharge port extensions 216 in FIG. 1 , it should be understood that each of the ribs 222 is positioned between adjacent fluid connection channels 220 (fluidically connecting adjacent discharge port extensions 216 ) and defines a rib thickness T Rib . Rib thickness T Rib It refers to the minimum distance between adjacent connecting channels 220 .

[0100] Furthermore, it should be appreciated that the inlet heat exchange manifold 212A defines an average rib thickness T Rib_Avg , average rib thickness T Rib_Avg Equal to the thickness of all ribs T Rib The sum is divided by the total number of ribs 222 in the inlet heat exchange manifold 212A.

[0101] It should also be appreciated that each of the plenum extension inlets 240 defines a plenum extension inlet hydraulic diameter Dh. Plenum_Inlet , each of the air chamber extension outlets 242 defines an air chamber extension outlet hydraulic diameter Dh Plenum_Exit Each of the discharge port extension inlets 244 defines a discharge port extension inlet hydraulic diameter Dh Offtake_Inlet , and each of the discharge port extension outlets 246 defines a discharge port extension outlet hydraulic diameter Dh Offtake_Exit .

[0102] Furthermore, it should be appreciated that the heat exchange manifold 212 defines (a) an average plenum extension inlet hydraulic diameter Dh Plenum_Inlet_Avg , which is equal to the hydraulic diameter Dh of the inlet of all air chamber extensions Plenum_Inlet The sum of the inlet plenum extension inlets 240 divided by the total number of inlet plenum extension inlets 240; (b) the average plenum extension outlet hydraulic diameter Dh Plenum_Exit_Avg , which is equal to the hydraulic diameter Dh of all air chamber extension outlets Plenum_Exit The sum of the inlet plenum extension outlets 242 divided by the total number of outlets 242 of the inlet plenum extension; (c) the average discharge port extension inlet hydraulic diameter Dh Offtake_Inlet_Avg , which is equal to the hydraulic diameter Dh of the inlet of all discharge outlet extensions Offtake_Inlet The sum of the outlet extension inlets 244 divided by the total number of outlet extension inlets 244; (d) the average outlet extension hydraulic diameter Dh Offtake_Exit_Avg , which is equal to the hydraulic diameter Dh of all discharge outlet extensions Offtake_Exit The sum of the above values ​​divided by the total number of outlets 246 of the exhaust extension; (e) the average air chamber extension length L Plenum_Avg , which is equal to the length L of all air chamber extensions Plenum The sum of the vent extension length L divided by the total number of plenum extensions 214; and (f) the average vent extension length L Offtake_Avg , which is equal to the length L of all discharge port extensions Offtake The sum is divided by the total number of sprue extensions 216 .

[0103] As previously mentioned, the inventors unexpectedly discovered during the course of heat exchanger and gas turbine engine design (i.e., designing gas turbine engines having heat exchangers with various plenum hydraulic diameter ratios, discharge port hydraulic diameter ratios, plenum to discharge port length ratios, average discharge port hydraulic diameter to rib thickness, and average plenum hydraulic diameter to rib thickness, and evaluating overall engine and heat exchanger performance) that significant relationships exist between (a) the plenum hydraulic diameter ratio, the discharge port hydraulic diameter ratio, and the plenum to discharge port length ratio, and (b) the average discharge port hydraulic diameter to rib thickness and the average plenum hydraulic diameter to rib thickness. These relationships can be considered as indicators of the ability of the gas turbine engine and heat exchanger to transfer relatively large amounts of heat from a hot fluid operating at high pressure to a heat sink (e.g., the working gas passages of the engine) without requiring a relatively heavy design that creates undesirable blockages in the working gas flow paths of the engine.

[0104] This relationship is applicable to heat exchanger assemblies having a core section with multiple heat exchange components and a heat exchange manifold required to provide high pressure hot fluid to the multiple heat exchanger components in an evenly distributed manner. This relationship relates the geometric relationship of the various extensions and / or connectors to the ability to withstand the desired high pressure, without unacceptable pressure drop, and with the desired distribution capacity.

[0105] In particular, the inventors have discovered that by balancing the inlet and outlet hydraulic diameters of the plenum extension, the inlet and outlet hydraulic diameters of the discharge port extension, and the length ratio of the plenum extension to the discharge port extension, a heat exchanger having the above-described desired characteristics can be achieved. Similarly, the inventors have discovered that by balancing the size of the inlet and outlet hydraulic diameters of the plenum extension and the average rib thickness, and the size of the inlet and outlet hydraulic diameters of the discharge port extension and the average rib thickness, a heat exchanger having the above-described desired characteristics can be achieved.

[0106] For example, the inventors of the present disclosure have discovered that by limiting the relationship of the above parameters to the upper end, a heat exchanger can achieve the above advantages without being unduly difficult to manufacture and including the required strength characteristics to accommodate the expected pressures in an efficient manner.

[0107] Thus, the relationships discovered below may identify improved gas turbine engine and heat exchanger configurations suitable for specific mission requirements taking into account efficiency, weight, thermal capacity requirements, complexity, reliability, and other factors that influence the optimal selection of gas turbine engine and heat exchanger configurations.

[0108] In addition to producing improved gas turbine engines and heat exchangers, as explained in detail above, by utilizing this relationship, the inventors have discovered that the number of suitable or feasible gas turbine engine and heat exchanger designs that can meet the above-mentioned design requirements can be greatly reduced, thereby facilitating a more rapid down-selection of designs to be considered when developing gas turbine engines and heat exchangers. This benefit provides more insight into the requirements for a given gas turbine engine and heat exchanger before the specific technical, integration and system requirements are fully developed. This benefit avoids late-stage redesigns.

[0109] The inventors have discovered that the desired relationship that provides an improved heat exchanger is the hydraulic diameter relationship (HDR) and the rib thickness relationship (RTR). HDR is expressed as:

[0110]

[0111] Among them Dh Offtake_Inlet_Avg is the hydraulic diameter of the average discharge extension inlet; Dh Offtake_Exit_Avg is the hydraulic diameter of the average discharge outlet extension; Dh Plenum_Inlet_Avg is the hydraulic diameter of the average air chamber extension inlet; Dh Plenum_Exit_Avg is the hydraulic diameter of the average air chamber extension outlet; L Plenum_Avg is the average air chamber extension length; and L Offtake_Avg is the average discharge port extension length.

[0112] RTR is expressed as:

[0113]

[0114] Where T Rib_Avg is the average rib thickness.

[0115] A heat exchanger assembly of the present disclosure configured to achieve the above benefits identified by HDR and RTR may have one or more of the following values:

[0116]

[0117] Reference now Figures 8 to 11 , various heat exchangers according to the present disclosure are provided. Figure 8 Provides includes and falls into Fig. 9 a table of values ​​corresponding to a number of heat exchangers within the range depicted in; and Fig. 9 A plot 300 of HDR value on the Y-axis 302 and the ratio of air chamber to exhaust port length on the X-axis 304 is provided. Similarly, Fig.10 Provides includes and falls into Fig.11 a table of values ​​corresponding to a number of heat exchangers within the range depicted in; and Fig.11A plot 400 of RTR value on the Y-axis 402 and plenum to exhaust length ratio on the X-axis 404 is provided.

[0118] Special References Fig. 9 , plot 300 depicts a first range 306 where the HDR value is greater than or equal to 0.00275 and less than or equal to 378, where the plenum to exhaust port length ratio is greater than or equal to 0.417 and less than or equal to 1.862. Fig. 9 Further depicted is a second range 308, wherein the HDR value is greater than or equal to 0.055 and less than or equal to 13, wherein the air chamber to exhaust port length ratio is greater than or equal to 0.497 and less than or equal to 1.601. Similarly, in Fig.11 , plot 400 depicts a first range 406 wherein the RTR value is greater than or equal to 0.315 and less than or equal to 375, wherein the plenum to exhaust port length ratio is greater than or equal to 0.417 and less than or equal to 1.862. Fig.11 Further depicted is a second range 408 wherein the RTR value is greater than or equal to 0.984 and less than or equal to 30.8, wherein the plenum to exhaust port length ratio is greater than or equal to 0.497 and less than or equal to 1.601.

[0119] Further aspects are provided by the subject matter of the following clauses:

[0120] A gas turbine engine defining a reference plane, the gas turbine engine comprising: a thermal management system having a thermal fluid component and a heat exchanger assembly, the thermal fluid component having a thermal fluid flow therethrough during operation of the gas turbine engine, the heat exchanger assembly comprising: a core section comprising a plurality of heat exchange components; and a heat exchange manifold comprising a first direction pressure vessel fluidly connected to the thermal fluid component and a second direction pressure vessel extending from the first direction pressure vessel, the first direction pressure vessel and the second direction pressure vessel each extending in the reference plane, the second direction pressure vessel fluidly connected to the first direction pressure vessel and to at least one of the plurality of heat exchange components.

[0121] A gas turbine engine according to any preceding clause, wherein the second direction pressure vessel is one of a plurality of second direction pressure vessels of the heat exchange manifold, wherein each of the plurality of second direction pressure vessels extends from the first direction pressure vessel in the reference plane, is fluidically connected to the first direction pressure vessel, and is fluidically connected to at least one of the plurality of heat exchange members.

[0122] A gas turbine engine as described in any preceding clause, wherein said plurality of second direction pressure vessels are further in fluid communication with each other.

[0123] A gas turbine engine as described in any preceding clause, wherein the heat exchange manifold includes a plurality of ribs extending between adjacent ones of the plurality of second directional pressure vessels.

[0124] A gas turbine engine as claimed in any preceding clause, wherein said plurality of heat exchange members extend perpendicular to said reference plane.

[0125] A gas turbine engine as in any preceding clause, wherein the first direction pressure vessel is one of a plurality of first direction pressure vessels of the heat exchange manifold, wherein each of the plurality of first direction pressure vessels is in parallel fluid communication with the hot fluid component.

[0126] A gas turbine engine according to any preceding clause, wherein the hot fluid component is a hot fluid source, and wherein the heat exchange manifold is an inlet heat exchange manifold configured to receive the hot fluid flow, and wherein the heat exchanger assembly further includes an outlet heat exchange manifold positioned opposite the inlet heat exchange manifold relative to the core section.

[0127] A gas turbine engine as claimed in any preceding clause, wherein the heat exchange manifold is a unitary component.

[0128] A gas turbine engine as claimed in any preceding clause, wherein the heat exchange manifold is formed by additive manufacturing.

[0129] A gas turbine engine as claimed in any preceding clause, wherein the heat exchange manifold is a high pressure thermal fluid manifold.

[0130] A gas turbine engine according to any preceding clause, wherein the gas turbine engine defines an axial direction and a radial direction, wherein the gas turbine engine includes an annular flow path, the annular flow path having an outer peripheral reference line along the radial direction at an axial position along the axial direction and an inner peripheral reference line along the radial direction at the axial position, and wherein the heat exchange manifold is at least partially positioned between the outer peripheral reference line and the inner peripheral reference line.

[0131] A gas turbine engine as claimed in any preceding clause, wherein the gas turbine engine defines a circumferential direction, and wherein the plurality of heat exchange members extend through the annular flow path in the circumferential direction.

[0132] A gas turbine engine as claimed in any preceding clause, wherein the annular flow path is a tertiary flow of the gas turbine engine.

[0133] A gas turbine engine according to any preceding clause, wherein the gas turbine engine further comprises a strut extending through the annular flow path and having an aerodynamic surface exposed to the annular flow path, wherein the heat exchange manifold is positioned inboard of the aerodynamic surface of the strut.

[0134] A gas turbine engine as claimed in any preceding clause, wherein the first directional pressure vessel is a plenum extension and wherein the second directional pressure vessel is a drain extension.

[0135] A gas turbine engine as claimed in any preceding clause, wherein the gas turbine engine defines a radial direction and an axial direction, and wherein the reference plane extends in the radial direction and in the axial direction.

[0136] A thermal management system defining a reference plane, the thermal management system comprising: a thermal fluid component having a thermal fluid flow therethrough during operation; and a heat exchanger assembly comprising: a core section comprising a plurality of heat exchange components; and a heat exchange manifold comprising a first direction pressure vessel in fluid communication with the thermal fluid component and a second direction pressure vessel extending from the first direction pressure vessel, the first direction pressure vessel and the second direction pressure vessel each extending in the reference plane, the second direction pressure vessel in fluid communication with the first direction pressure vessel and in fluid communication with at least one of the plurality of heat exchange components.

[0137] A thermal management system according to any preceding clause, wherein the second direction pressure vessel is one of a plurality of second direction pressure vessels of the heat exchange manifold, wherein each of the plurality of second direction pressure vessels extends from the first direction pressure vessel in the reference plane, is fluidically connected to the first direction pressure vessel, and is fluidically connected to at least one of the plurality of heat exchange members.

[0138] A thermal management system as recited in any preceding clause, wherein the plurality of second direction pressure vessels are further in fluid communication with each other.

[0139] A thermal management system as recited in any preceding clause, wherein the heat exchange manifold comprises a plurality of ribs extending between adjacent ones of the plurality of second direction pressure vessels.

[0140] A heat exchanger assembly of a thermal management system having a thermal fluid component, the heat exchanger assembly comprising: a core section, the core section comprising a plurality of heat exchange components; and a heat exchange manifold, the heat exchange manifold comprising: one or more plenum extensions, the one or more plenum extensions configured to be in fluid communication with the thermal fluid component, the one or more plenum extensions defining an average plenum inlet hydraulic diameter (Dh Plenum_Inlet_Avg ), average air chamber outlet hydraulic diameter (Dh Plenum_Exit_Avg ) and the average air chamber length (L Plenum_Avg ); a plurality of discharge port extensions extending from the one or more plenum extensions and in fluid communication with the plurality of heat exchange members, the plurality of discharge port extensions defining an average discharge port inlet hydraulic diameter (Dh Offtake_Inlet_Avg ), average outlet hydraulic diameter (Dh Offtake_Exit_Avg ) and the average discharge port length (L Offtake_Avg ); wherein the heat exchange manifold defines a hydraulic diameter relationship (HDR) greater than 0.00275 and less than 378, wherein HDR is equal to:

[0141]

[0142] A heat exchanger assembly according to any of the preceding clauses, wherein the heat exchange manifold further includes one or more ribs, wherein the one or more ribs extend between adjacent discharge port extensions among the plurality of discharge port extensions, or between adjacent plenum extensions among the one or more plenum extensions, or between adjacent discharge port extensions among the plurality of discharge port extensions and between adjacent plenum extensions among the one or more plenum extensions.

[0143] A heat exchanger assembly according to any preceding clause, wherein the one or more ribs define an average rib thickness (T Rib_Avg ), wherein the heat exchange manifold defines a rib thickness relationship (RTR) greater than 0.315 and less than 375, wherein the RTR is equal to:

[0144]

[0145] A heat exchanger assembly according to any preceding clause, wherein Between 0.27 and 23, and where Between 0.27 and 22.

[0146] A heat exchanger assembly according to any preceding clause, wherein Between 0.78 and 6.02, and where Between 0.86 and 6.

[0147] A heat exchanger assembly according to any preceding clause, wherein Between 0.045 and 23.

[0148] A heat exchanger assembly according to any preceding clause, wherein Between 0.25 and 4.

[0149] A heat exchanger assembly according to any preceding clause, wherein Between 0.045 and 23.

[0150] A heat exchanger assembly according to any preceding clause, wherein Between 0.25 and 4.

[0151] A heat exchanger assembly according to any preceding clause, wherein Between 0.02 and 5.

[0152] A heat exchanger assembly according to any preceding clause, wherein Between 0.4 and 1.72.

[0153] A heat exchanger assembly as recited in any preceding clause, wherein each of said plurality of drain extensions extends from said one or more plenum extensions in a reference plane of said thermal management system.

[0154] A heat exchanger assembly of a thermal management system having a thermal fluid component, the heat exchanger assembly comprising: a core section, the core section comprising a plurality of heat exchange components; and a heat exchange manifold, the heat exchange manifold comprising: one or more plenum extensions, the one or more plenum extensions configured to be in fluid communication with the thermal fluid component, the one or more plenum extensions defining an average plenum inlet hydraulic diameter (Dh Plenum_Inlet_Avg ) and the average hydraulic diameter of the air chamber outlet (Dh Plenum_Exit_Avg ); a plurality of discharge port extensions extending from the one or more plenum extensions and in fluid communication with the plurality of heat exchange members, the plurality of discharge port extensions defining an average discharge port inlet hydraulic diameter (Dh Offtake_Inlet_Avg ) and the average outlet hydraulic diameter (Dh Offtake_Exit_Avg ); one or more ribs extending between adjacent ones of the plurality of stomal extensions, or between adjacent ones of the one or more plenum extensions, or between adjacent ones of the plurality of stomal extensions and between adjacent ones of the one or more plenum extensions; wherein the one or more ribs define an average rib thickness (T Rib_Avg), wherein the heat exchange manifold defines a rib thickness relationship (RTR) greater than 0.315 and less than 375, wherein the RTR is equal to:

[0155]

[0156] A heat exchanger assembly according to any preceding clause, wherein Between 0.27 and 23, and where Between 0.27 and 22.

[0157] A heat exchanger assembly according to any preceding clause, wherein Between 0.78 and 6.02, and where Between 0.86 and 6.

[0158] A heat exchanger assembly according to any preceding clause, wherein the plurality of discharge port extensions further define an average discharge port length (L Offtake_Avg ), wherein the one or more air chamber extensions further define an average air chamber length (L Plenum_Avg ).

[0159] A heat exchanger assembly as described in any preceding clause, wherein the heat exchange manifold defines a hydraulic diameter relationship (HDR) greater than 0.00275 and less than 378, wherein HDR is equal to:

[0160]

[0161] A heat exchanger assembly according to any preceding clause, wherein Between 0.045 and 23.

[0162] A heat exchanger assembly according to any preceding clause, wherein Between 0.045 and 23.

[0163] A heat exchanger assembly according to any preceding clause, wherein Between 0.02 and 5.

[0164] This written description uses examples to disclose the present disclosure, including the best mode, and also to enable any person skilled in the art to practice the present disclosure, including making and using any device or system and performing any combined methods. The patentable scope of the present disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. These other examples are intended to fall 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 do not differ substantially from the literal language of the claims.

Claims

1. A gas turbine engine defining a reference plane, characterized in that: The gas turbine engine comprises: A thermal management system having a thermal fluid component having a thermal fluid flow therethrough during operation of the gas turbine engine and a heat exchanger assembly, the thermal fluid component having a thermal fluid flow therethrough during operation of the gas turbine engine, the heat exchanger assembly comprising: a core section including a plurality of heat exchange components; and A heat exchange manifold, the heat exchange manifold comprising a first direction pressure vessel fluidly connected to the thermal fluid component and a second direction pressure vessel extending from the first direction pressure vessel, the first direction pressure vessel and the second direction pressure vessel each extending in the reference plane, the second direction pressure vessel fluidly connected to the first direction pressure vessel and fluidly connected to at least one of the plurality of heat exchange components.

2. The gas turbine engine according to claim 1, characterized in that in, The second direction pressure vessel is one of a plurality of second direction pressure vessels of the heat exchange manifold, wherein each of the plurality of second direction pressure vessels extends from the first direction pressure vessel in the reference plane, is fluidically connected to the first direction pressure vessel, and is fluidically connected to at least one of the plurality of heat exchange members.

3. The gas turbine engine according to claim 2, characterized in that in, The plurality of second direction pressure vessels are further in fluid communication with each other.

4. The gas turbine engine according to claim 2, characterized in that in, The heat exchange manifold includes a plurality of ribs extending between adjacent ones of the plurality of second direction pressure vessels.

5. The gas turbine engine according to claim 1, characterized in that in, The plurality of heat exchange members extend perpendicular to the reference plane.

6. The gas turbine engine according to claim 1, characterized in that in, The first direction pressure vessel is one of a plurality of first direction pressure vessels of the heat exchange manifold, wherein each of the plurality of first direction pressure vessels is in parallel fluid communication with the thermal fluid member.

7. The gas turbine engine according to claim 1, characterized in that in, The thermal fluid component is a thermal fluid source, and wherein the heat exchange manifold is an inlet heat exchange manifold configured to receive the thermal fluid flow, and wherein the heat exchanger assembly further includes an outlet heat exchange manifold positioned opposite the inlet heat exchange manifold relative to the core section.

8. The gas turbine engine according to claim 1, characterized in that in, The heat exchange manifold is a unitary component.

9. The gas turbine engine according to claim 8, characterized in that in, The heat exchange manifold is formed by additive manufacturing.

10. The gas turbine engine according to claim 1, characterized in that in, The heat exchange manifold is a high pressure thermal fluid manifold.

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