Metal-Plated ACM Housing With Thermally Adaptive 3D-Printed Structure
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Solution Overview
Problem
Housings for air cycle machines (ACM) manufactured using exotic materials are expensive and heavy, and materials with different coefficients of expansion can separate or fail due to thermal stress.
Innovation Solution
A method involving additive manufacturing of a plastic housing with discrete sections made from thermoplastic polymers having different coefficients of thermal expansion (CTE), combined with metal plating to control thermal expansion and contraction, using techniques like stereolithography or fused deposition modeling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If housings are manufactured using exotic materials to achieve high strength and thermal stability, then the housing strength and thermal resistance are improved, but the housing weight increases and manufacturing cost increases
Solution Approach 1:
The housing combines plastic base material with metal reinforcement coatings to create a composite structure that achieves the strength of exotic materials while maintaining the weight advantages of plastic components
Solution Approach 2:
Metal reinforcement is applied selectively only to specific areas of the housing where high strength is needed, rather than using exotic materials throughout the entire housing structure
2Weight of moving object
If housings are additively manufactured from plastic and coated with strengthening materials, then the housing weight is reduced and manufacturing cost is lowered, but the different materials separate or fail due to different coefficients of expansion
Solution Approach 1:
The patent modifies the surface properties of the plastic housing through chemical treatment or surface preparation to change its thermal and surface characteristics, enabling better adhesion of the metal coating despite thermal expansion differences
Solution Approach 2:
A transition layer or surface treatment is introduced between the plastic housing and metal coating to mediate the thermal expansion mismatch and prevent coating failure
3Ease of manufacture
If uniform material is used throughout the housing to simplify manufacturing, then the manufacturing process is simplified, but the housing cannot adapt to varying thermal conditions in different sections
Solution Approach 1:
The housing incorporates different materials or material properties in different sections to match the specific thermal and mechanical requirements of each area, such as using materials with different coefficients of thermal expansion in sections adjacent to different components
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a cost-effective, lightweight, and abrasion-resistant housing that optimizes thermal deflections, reduces induced stress, and enhances performance by controlling thermal expansion and contraction.
Implementation Method 1
printing, layer by layer, the housing base, by printing first and second thermoplastic polymer surfaces, respectively from first and second thermoplastic polymers
Implementation Method 2
forming an upper support section on the housing by depositing on the lower support section, along each of the discrete sections, via electrolysis deposition, a metallic coating
Data Source
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AI summary
A method of forming a housing for an ACM (10), having steps of: forming a base (80): a first section (100) adjacent to a seal (23) of an ACM compressor rotor (22) when installed; a second section (100) that is fixed to an ACM forward frame member (25) when installed; a third section (100) adjacent to a bearing (32) and sleeve (58) disposed around an ACM compressor rotor shaft (54) when installed, forming the base (80) includes: printing thermoplastic polymer surfaces (200, 210) from thermoplastic polymers that are disposed against each other, the thermoplastic polymer surface having differing CTEs; forming a lower support section (82) on the base (80) by printing, layer by layer, along the plurality of discrete sections of the base (80) a mixture of a third thermoplastic polymer and a catalyst (240) formed with metal; and forming an upper support section (84) on the housing (46) by depositing on the lower support section (82), along each of the discrete sections, via electrolysis deposition, a metallic coating.