Aircraft Electronics Cooling Loop for Startup and In-Flight Heat Rejection
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Solution Overview
Problem
Conventional thermal management systems for power electronics in the aerospace industry are bulky and inefficient during startup, as they rely on bypass air for cooling, which is not available during motionless activities, and fail to meet the demands of increasing power levels while maintaining compactness and lightweight requirements.
Innovation Solution
A compact and lightweight thermal management system for aircraft electronics that uses a coolant passage with air-coolant and fuel-coolant heat exchangers, pumps, and a generator to manage heat before and after engine startup, leveraging fan bypass air and ram air flow for efficient cooling, eliminating the need for fuel-based cooling during flight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional thermal management systems use bypass air for cooling electronics, then cooling effectiveness is improved during operation, but the system becomes bulky with high volume and cannot provide cooling during startup when no bypass air is available
Solution Approach 1:
The thermal management system is designed to perform multiple cooling functions using different heat exchangers: a first heat exchanger provides cooling during startup when bypass air is unavailable, and a second heat exchanger provides cooling during operation when bypass air is available. This multi-functional approach ensures reliable cooling effectiveness across all operational phases while maintaining a compact integrated structure rather than requiring separate bulky systems for each phase.
Solution Approach 2:
The patent combines multiple heat exchangers (first heat exchanger for startup cooling, second heat exchanger for operational cooling) and the bi-directional rectifier into a single integrated thermal management system. This merging of components into one compact unit reduces the overall system volume compared to having separate cooling systems for different operational phases, while maintaining effective cooling throughout.
2Volume of moving object
If thermal management systems are designed for compactness and lightweight, then volume and weight constraints are satisfied, but cooling capability during startup and high power operations becomes insufficient
Solution Approach 1:
The compact thermal management system incorporates multiple heat exchangers that provide different cooling capabilities: the first heat exchanger handles startup cooling when bypass air is unavailable, and the second heat exchanger handles operational cooling when bypass air is available. This multi-functionality ensures adequate cooling capability across all power levels and operational phases within a compact volume.
Solution Approach 2:
The system dynamically adapts its cooling approach based on operational phase: during startup, it uses the first heat exchanger with available airflow, and during operation, it switches to the second heat exchanger utilizing bypass air. This dynamic adaptation allows the compact system to meet high power cooling demands at different times without requiring a large, heavy system designed for maximum power continuously.
3Reliability
If conventional systems rely on bypass air for cooling, then cooling is effective during operation, but no cooling is available during startup or motionless activities when bypass air is not available
Solution Approach 1:
The thermal management system incorporates both a first heat exchanger for startup cooling and a second heat exchanger for operational cooling within a single integrated structure. This multi-functional design ensures cooling availability during both startup (when bypass air is unavailable) and operation (when bypass air is available), without requiring entirely separate cooling systems for each phase.
Solution Approach 2:
The patent merges the startup cooling function and operational cooling function into one integrated thermal management system with multiple heat exchangers. This combination provides continuous cooling availability across all operational phases while avoiding the complexity of having completely separate, independent cooling systems for startup and operation.
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 solution provides reliable, high-performance, and compact cooling for bi-directional rectifiers, enabling engine start without main fan airflow and reducing weight and size, while ensuring safety by avoiding fuel use for cooling during flight operations.
Implementation Method 1
a body having a coolant passage defined by at least a first wall and a second wall, wherein the first wall being in thermal communication with an electronic device
Implementation Method 2
a first heat exchanger fluidically connected to the coolant passage configured to receive the coolant from the coolant passage, a second heat exchanger fluidically connected to the first heat exchanger
Data Source
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AI summary
An thermal management system including, a body (202) having a coolant passage (204) in thermal communication with an electronic device (110), a first heat exchanger (116) fluidically connected to the coolant passage configured to receive the coolant from the coolant passage, a second heat exchanger (120) fluidically connected to the first heat exchanger, and a generator (122) fluidically connected to the second heat exchanger.