Integrated Aircraft Air Cycle Machine Shell for Compact Airflow Routing

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Solution Overview

Problem

Existing aircraft environmental control systems (ECS) face inefficiencies due to complex ducting and valve arrangements in traditional air cycle machines (ACM), leading to increased weight, size, and drag penalties, as well as suboptimal performance from centrifugal and mixed flow compressors and turbines.

Innovation Solution

An integrated air cycle machine (ACM) design featuring a shell that surrounds a compressor and turbine, with axial stages and diverging/converging shell portions to optimize airflow, and optionally includes a front heat exchanger and water collector, formed by unitary half-shells via additive manufacturing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If traditional ACM configurations use complex ducting and valve arrangements, then the system can accommodate centrifugal and mixed flow compressors and turbines, but the weight and size penalty increases significantly

Engineering Contradiction:

Improvecompressor and turbine type accommodationVSAvoidACM weight

Core Design Contradiction:

Adaptability or versatilityVSWeight of stationary object

Solution Approach 1:

The patent integrates the ducting and valve arrangements directly into the shell structure that houses the compressor and turbine, merging previously separate components into a unified housing. This eliminates the need for additional complex ducting and reduces the overall weight while maintaining adaptability to different compressor and turbine types.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The shell structure is designed to serve multiple functions simultaneously: it houses the compressor and turbine, provides the necessary ducting pathways, and incorporates valve arrangements. This multi-functional design reduces the number of separate components needed, thereby reducing weight while maintaining system versatility.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If traditional ACM configurations use complex ducting and valve arrangements, then the system can accommodate various compressor and turbine types, but the system size increases

Engineering Contradiction:

Improvecompressor and turbine type accommodationVSAvoidACM volume

Core Design Contradiction:

Adaptability or versatilityVSVolume of stationary object

Solution Approach 1:

By merging the ducting and valve arrangements into the shell structure, the patent eliminates the need for separate external ducting components, thereby reducing the overall system volume while maintaining the ability to accommodate various compressor and turbine types.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The ducting pathways and valve arrangements are nested within the shell structure that houses the compressor and turbine, similar to a nested doll configuration. This nesting approach allows the system to maintain functionality while minimizing the external volume required.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Volume of stationary object

If centrifugal and mixed flow compressors and turbines are used in ACM, then spatial requirements are reduced compared to axial stages, but operational efficiency decreases

Engineering Contradiction:

Improvecompressor and turbine volumeVSAvoidcompressor and turbine efficiency

Core Design Contradiction:

Volume of stationary objectVSProductivity

Solution Approach 1:

The patent optimizes the local flow conditions within the shell structure by carefully designing the ducting pathways and inlet/outlet configurations to match the specific requirements of centrifugal and mixed flow compressors and turbines. This local optimization ensures efficient operation despite the compact size, addressing the efficiency concern while maintaining the spatial advantages.

Inventive Principle:

Principle #3Local quality

4Adaptability or versatility

If traditional ACM configurations are used, then existing system compatibility is maintained, but drag penalty increases

Engineering Contradiction:

Improvesystem compatibilityVSAvoiddrag

Core Design Contradiction:

Adaptability or versatilityVSObject-generated harmful factors

Solution Approach 1:

By integrating all necessary ducting and valve arrangements into the shell structure, the patent creates a more streamlined external profile with fewer protruding components. This reduces the drag penalty while maintaining internal compatibility with existing compressor and turbine designs.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS12560098B2Integrated air cycle machine for an environmental control system of an aircraft

Publication Date: 2026.02.24 HAMILTON SUNDSTRAND CORP

AI summary

An air cycle machine (ACM), having a heat exchanger having a front end and an aft end; a compressor at the front end of the heat exchanger; a turbine at the aft end of the heat exchanger; a shell having a shell front part that surrounds the compressor and defines a shell inlet, a shell aft part that surrounds the turbine and defines a shell outlet, and a shell middle part that surrounds the heat exchanger, wherein a flow passage is defined within the shell and around the compressor, through the heat exchanger, and around the turbine; and a shaft extending between the compressor and the turbine that couples the compressor and the turbine.