Actively Cooled Heat Exchanger Tiles for Airframe Heat Flux
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Solution Overview
Problem
Supersonic and hypersonic aircraft face challenges in managing high heat fluxes without accumulating thermal energy, as passive heat shields are heavy and active cooling systems are not implemented effectively, leading to weight and thermal stress issues.
Innovation Solution
An aircraft structure with actively cooled heat exchanger tiles secured by fasteners, embedding fluidic channels and thermal insulation material, allowing for lightweight and durable active cooling, reducing thermal stress and weight compared to passive solutions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If passive heat shields are used to protect the aircraft from overheating, then thermal protection is improved, but aircraft weight increases significantly
Solution Approach 1:
The patent replaces passive mechanical heat shields with an active cooling system using heat exchanger tiles containing fluidic channels. Instead of relying on thick insulating materials to block heat, the system circulates coolant through the tiles to actively remove heat from the aircraft skin, significantly reducing weight while maintaining thermal protection
Solution Approach 2:
The patent changes the thermal management approach from passive insulation (high thermal resistance) to active heat removal (controlled heat transfer parameters). By adjusting coolant flow rate, temperature, and channel configuration, the system dynamically manages heat flux to protect the aircraft structure without requiring heavy passive shielding
2Loss of energy
If active cooling systems with heat exchangers are installed on the aircraft structure, then heat evacuation capability is improved, but thermal stress and structural complexity increase
Solution Approach 1:
The patent divides the aircraft skin into modular heat exchanger tiles that can be independently cooled. Each tile contains its own fluidic channels and can be adjusted separately, allowing localized thermal management and reducing overall thermal stress on the structure by distributing heat loads across multiple independent units
Solution Approach 2:
The patent implements a dynamic cooling system where coolant flow can be adjusted in real-time based on thermal conditions. The system responds to varying heat fluxes during flight by modifying flow rates and temperatures, enabling adaptive thermal stress management rather than rigid static cooling
3Temperature
If thermal insulation material is placed between the aircraft structure and heat exchanger tiles, then thermal protection of the structure is improved, but fastening complexity and device complexity increase
Solution Approach 1:
The patent combines the thermal insulation function with the structural fastening system by integrating insulation material directly into the tile mounting assembly. The insulation is positioned between the tile and aircraft structure as part of the same assembly operation, eliminating separate insulation installation steps and reducing overall system complexity
Solution Approach 2:
The patent designs the fastening system to simultaneously perform multiple functions: securing the heat exchanger tile, providing thermal insulation, and managing thermal expansion. The integrated design allows the same components to serve multiple purposes, reducing the need for additional dedicated insulation fixtures or fasteners
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 efficient, lightweight active cooling that reduces thermal stress and weight, enhancing aircraft performance and fuel efficiency by using fasteners to secure tiles with integrated fluidic channels and insulation, optimizing thermal management.
Implementation Method 1
a fluid-based cooling circuit (70-73) and heat exchanger tiles (25)... each tile (25) embeds one or more fluidic channels (254), which are connected to the fluid-based cooling circuit (70-73), whereby the thermal exchange system is adapted to actively cool the tiles (25), in operation
Implementation Method 2
The thermal insulation material (26) extends between the aircraft structure (20) and the heat exchanger tiles (25)... the thermal insulation material (26) is clamped on either side by the heat exchanger tiles (25) and by the aircraft structure (20)
Data Source
Figure 1A~1B
Figure 2
Figure 3~4
AI summary
The invention is notably directed to an aircraft (10), which includes an aircraft structure (20), a thermal exchange system, a thermal insulation material (26), and fasteners (32, 35). The thermal exchange system includes a fluid-based cooling circuit (70 - 73) and heat exchanger tiles (25). The latter cover, at least partly, the aircraft structure. They may thus form the skin of the aircraft. The fasteners (32, 35) secure the tiles (25) to the aircraft structure. Each tile of the heat exchanger tiles embeds one or more fluidic channels (254), which are connected to the fluid-based cooling circuit, whereby the thermal exchange system is adapted to actively cool the tiles, in operation. Remarkably, the thermal insulation material (26) extends between the aircraft structure and the heat exchanger tiles. The thermal insulation material (26) is clamped on either side by the heat exchanger tiles (25) and by the aircraft structure (20), thanks to the fasteners (32, 35). The latter can for instance be bolted joints, which extend from central areas of the tiles. Some of the fasteners may embed sensors (40The invention is further directed to methods of operating such an aircraft. Such methods operate the fluid-based cooling circuit to circulate a cooling fluid through the fluidic channels (254) of the heat exchanger tiles (25) to cool them down. The present methods may further harness aerodynamic heating to help evaporate a liquid coolant and form the cooling fluid as a gas.