Aircraft Propulsion Cooling Layout for Compact High-Power Electronics
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Solution Overview
Problem
Current aircraft propulsion systems face challenges in efficiently packaging and cooling the high-power electronics and motors, particularly in managing thermal energy and airflow during various flight configurations, which affects power density and efficiency.
Innovation Solution
The proposed solution involves a compact cooling system with integrated cold plates and thermal interface components, such as thermal coins, to efficiently transfer heat from high-power inverter boards and motors, combined with a radiator design that adjusts airflow based on flight configuration to optimize heat rejection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If compact packaging of high-power electronics and motors is implemented, then power density is improved, but thermal management becomes more difficult
Solution Approach 1:
The patent merges the cooling system with the propulsion unit structure by integrating cold plates directly into the housing that contains the motor and inverter boards. This consolidation allows compact packaging while maintaining effective thermal management through shared structural components that serve both mechanical support and heat dissipation functions.
Solution Approach 2:
The patent introduces thermal interface materials as intermediaries between the heat-generating components (inverter boards, motors) and the cold plates. These interface materials facilitate efficient heat transfer from the electronics to the cooling system, enabling compact packaging while maintaining effective thermal coupling despite close proximity of components.
2Adaptability or versatility
If fixed cooling system design is used, then manufacturing simplicity is maintained, but adaptability to different flight configurations is reduced
Solution Approach 1:
The patent implements a dynamic cooling system where the radiator can be positioned at different locations relative to the propulsion unit depending on the flight configuration. The system adapts between forward flight mode (radiator in forward position) and hover mode (radiator in rearward position), allowing the same cooling system to serve multiple operational requirements without requiring completely different designs for each mode.
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 configuration enhances power density and efficiency by effectively managing thermal energy and airflow, improving the overall performance and reliability of the aircraft propulsion system across different flight modes.
Implementation Method 1
a first cold plate (322) having a first broad face arranged adjacent to the inverter board (324, 340)
Implementation Method 2
coolant path (320) that fluidly connects the motor (302) and the first cold plate (322)
Implementation Method 3
a first thermal coin (606) arranged between the inverter board (324, 340) and the first cold plate (322)
Implementation Method 4
radiator (310) arranged to face forward in the forward configuration and arranged to face rearward in the hover configuration
Implementation Method 5
radiator (310) arranged to face forward in the forward configuration and arranged to face rearward in the hover configuration
Data Source
AI summary
An aircraft propulsion unit includes an electric motor, at least one accessory unit used for operating the electric motor, an inverter module, the inverter module including a plurality of inverters for powering the electric motor and the at least one accessory unit, and a cooling system coupled to the electric motor and the inverter module, the cooling system comprising a coolant path for circulating a coolant through or adjacent to the electric motor and the at least one accessory unit.