Charge Air Heat Exchanger Layout for Fuel Cell Aircraft Cooling
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Solution Overview
Problem
Aircraft using hydrogen fueled fuel cells face challenges in integrating liquid hydrogen systems, particularly in determining safe tank locations and packaging thermal management and fuel cell stack systems efficiently.
Innovation Solution
The proposed solution involves a configuration for a hydrogen fuel cell aircraft with distributed systems, including the use of six engine nacelles to reduce volume requirements and increase redundancy, as well as a high temperature proton exchange membrane fuel cell to minimize heat exchanger sizing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If liquid hydrogen tanks are integrated into the aircraft structure, then weight is reduced and space is optimized, but safety risks increase due to the extremely low storage temperature of -253 degrees C
Solution Approach 1:
The aircraft is divided into multiple nacelles (at least two, preferably six) with fuel cell stacks distributed across them. This segmentation allows the hydrogen storage system to be distributed rather than centralized, reducing the risk associated with any single tank location while maintaining weight efficiency.
Solution Approach 2:
The patent explores integrating hydrogen tanks into the aircraft fuselage structure rather than placing them as separate external components. This structural integration optimizes space utilization and reduces overall aircraft weight while maintaining safety through careful structural design and thermal management.
2Volume of moving object
If thermal management systems are packaged with fuel cell stacks in nacelles, then volume requirements are reduced and integration is improved, but heat exchanger sizing becomes more challenging
Solution Approach 1:
The thermal management system is merged with the fuel cell stack packaging within the nacelle structure. The heat exchangers are integrated into the same volume space as the fuel cell stacks, combining cooling functions with power generation components to reduce overall nacelle volume requirements.
Solution Approach 2:
The heat exchangers serve multiple functions: they cool the fuel cell stacks, precondition the air before it enters the fuel cells, and potentially recover heat for other aircraft systems. This multi-functionality reduces the need for separate dedicated cooling components, simplifying the overall design.
3Use of energy by moving object
If compressed air is cooled before entering the fuel cell stack, then fuel cell efficiency is improved, but additional cooling stages increase system complexity
Solution Approach 1:
The heat exchangers in the nacelles perform dual functions: they cool the compressed air to improve fuel cell efficiency while simultaneously serving as the primary cooling system for the fuel cell stacks themselves. This eliminates the need for separate cooling circuits, reducing system complexity.
Solution Approach 2:
The fuel cell stack cooling system uses the compressed air itself as the coolant medium. The compressed air is cooled by passing through heat exchangers that are thermally coupled to the fuel cell stacks, allowing the air to absorb excess heat from the stacks while being conditioned for optimal fuel cell performance.
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 enables efficient packaging and integration of thermal management and fuel cell systems, reducing electric motor power requirements and minimizing weight and drag, while also providing redundancy and improved aerodynamic performance.
Implementation Method 1
the charge air heat exchanger cools the compressed air in which cooling the compressed air forms cooler compressed air
Implementation Method 2
the charge air intercooler cools the cooler compressed air in which cooling the cooler compressed air forms cooled compressed air
Implementation Method 3
The hydrogen stored in these tanks can then be sent to fuel cells for use in generating electricity to power propulsion systems and other systems in aircraft. These fuel cells are electrochemical devices that convert the hydrogen and oxygen obtained from the air into electricity
Data Source
AI summary
An aircraft air management system comprises an air heat exchanger; an intercooler; and a conduit system connected to the air heat exchanger, the intercooler, and a fuel cell stack. Heated air flows through the conduit system to the air heat exchanger. The air heat exchanger is configured to cool the heated air to form cooler air, wherein the cooler air flows from the air heat exchanger through the conduit system to the intercooler; and the intercooler is configured to cool the cooler air to form cooled air, wherein the cooled air flows from the intercooler through the conduit system to the fuel cell stack.