Aerospace Structural Elements as Thermal Bus for Heat Dissipation
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Solution Overview
Problem
Current thermal management systems in aerospace vehicles face challenges such as increased weight, complexity, and reduced efficiency due to the lack of integrated heat transfer in electrically powered subsystems, particularly in More Electric Aircraft, where thermally conductive composite materials have limited heat dissipation capabilities and stealth requirements restrict design options.
Innovation Solution
A structurally integrated thermal management system where the aerospace vehicle's structural elements act as a thermal bus, thermally connected to heat-generating components, using thermal bosses and thermally conductive materials like pyrolytic graphite and carbon nanotubes to efficiently dissipate heat from electrical components into the vehicle's structure and ambient air.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If thermally conductive composite materials are used for aircraft structural members to reduce weight, then weight is reduced, but heat dissipation capability deteriorates
Solution Approach 1:
The patent merges the structural function and thermal management function into a single integrated system. The structural members (spar, rib, skin) serve dual purposes: providing mechanical support and acting as thermal conduction pathways. This eliminates the need for separate cooling systems while maintaining weight reduction benefits of composite materials.
Solution Approach 2:
The structural members are designed to perform multiple functions simultaneously. The same composite materials that provide structural support and weight reduction also serve as thermal conduction paths when integrated with thermally conductive elements, allowing a single component to fulfill both structural and thermal management roles.
2Temperature
If a centralized coolant loop is used to handle thermal load from distributed components, then heat dissipation is improved, but system complexity and weight increase
Solution Approach 1:
The patent extracts the thermal management function from the structural members and transfers it to dedicated thermally conductive elements (such as thermally conductive composite materials or metal inserts) integrated within the structure. This allows the structural members to maintain their primary structural function while the thermally conductive elements handle heat dissipation, reducing overall system complexity compared to a centralized coolant loop.
Solution Approach 2:
The structural members with integrated thermally conductive elements serve their own thermal management needs directly. Heat generated by electrical components is conducted away through the structural members themselves, which act as heat sinks, eliminating the need for external coolant loops and complex thermal management systems.
3Weight of moving object
If electric actuators are used instead of hydraulic actuators, then system weight is reduced, but heat generation increases
Solution Approach 1:
The patent introduces thermally conductive composite materials and thermal management elements as intermediaries between the electric actuators and the aircraft structure. These intermediaries facilitate efficient heat transfer from the actuators to the structural members, which act as heat sinks, thereby managing the heat generated by electric actuators without requiring additional cooling systems.
4Object-affected harmful factors
If stealth requirements are implemented with smooth exterior surfaces and minimum penetrations, then detection avoidance is improved, but thermal management options are reduced
Solution Approach 1:
The patent merges thermal management functionality with the aircraft's structural members and existing skin surfaces. By utilizing the structural members as thermal conduction pathways and incorporating thermally conductive elements within the existing structure, the system achieves effective heat dissipation without requiring additional penetrations or external thermal management components that would compromise the smooth exterior surface required for stealth characteristics.
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
This approach effectively manages thermal loads by utilizing the vehicle's structure for heat dissipation, reducing weight and complexity while maintaining stealth characteristics, and enhancing heat transfer efficiency through the use of advanced materials and micro-channel assemblies.
Implementation Method 1
the heat-generating electrical component is directly mechanically attached to the structural element by a thermal boss, which provides a thermally conductive element for transmitting heat from the electrical component into the structural element
Implementation Method 2
the structural elements of the aerospace vehicle include thermally conductive portions or layers, which are particularly configured to conduct thermal energy away from the heat-generating electrical component through the structural element
Implementation Method 3
heat from those components is directed away from the component by the structure of the vehicle itself, into lower temperature surfaces of the vehicle
Data Source
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AI summary
Disclosed examples include a structurally integrated thermal management system that uses the structure of an aerospace vehicle as part of the heat dissipation system. In this system, structural elements of the aerospace vehicle function as a thermal bus, and are thermally connected with heat-generating electrical components, so that heat from those components is directed away from the component by the structure of the vehicle itself, into lower temperature surfaces of the vehicle.