Coalescing Tube Bundle Elbow for Aircraft Water Vapor Separation
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Solution Overview
Problem
Environmental control systems without condensers in aircraft face reliability issues due to water vapor leading to erosion, icing, and turbine imbalance, as they lack components to effectively condense and collect water vapor.
Innovation Solution
A coalescing tube bundle elbow with a curved profile and channels that condenses water vapor from a gaseous to a liquid state, integrated with a swirl vane section and water collection system to separate and collect the liquid portion, replacing traditional condenser heat exchangers and minimizing system weight and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional condenser heat exchanger is used to condense water vapor, then water vapor condensation efficiency is improved, but system weight and complexity increase
Solution Approach 1:
The patent combines the condensation function and water collection function into a single integrated coalescing tube bundle elbow component. The tube bundle structure serves as both the condensation surface and the water collection pathway, eliminating the need for separate condenser and water collector components. This merging approach maintains effective water vapor condensation while reducing system complexity and weight.
Solution Approach 2:
The coalescing tube bundle elbow performs multiple functions simultaneously: it acts as a flow direction changer, a condensation surface, and a water collection device. The curved elbow geometry redirects airflow while the tube bundle structure provides condensation surfaces and collects condensed water in one integrated component, achieving multi-functionality that reduces overall system complexity.
2Device complexity
If system components are eliminated to decrease weight and complexity, then system weight and complexity are reduced, but reliability decreases due to insufficient water vapor condensation
Solution Approach 1:
The tube bundle structure creates a porous-like network of condensation surfaces within the elbow. The multiple tubes provide extensive surface area for water vapor condensation while maintaining an integrated structure that combines condensation and water collection functions. This approach ensures reliable water vapor condensation without requiring additional separate components.
Solution Approach 2:
The patent utilizes the three-dimensional space within the elbow by incorporating a bundle of tubes arranged in a specific pattern. This dimensional arrangement maximizes the condensation surface area within the available volume, ensuring effective water vapor condensation while maintaining a compact integrated structure that does not require additional components.
3Reliability
If a coalescing tube bundle elbow with curved profile is used, then water vapor condensation and flow direction change are achieved, but manufacturing complexity increases
Solution Approach 1:
The elbow employs a curved profile instead of sharp angles to redirect airflow. This curvature facilitates smooth flow transition and effective condensation while being more amenable to standard manufacturing processes such as bending or forming operations. The curved geometry reduces stress concentrations and simplifies fabrication compared to complex angular transitions.
Solution Approach 2:
The tube bundle is divided into multiple individual tubes that can be manufactured separately and then assembled into the elbow structure. This segmentation allows each tube to be produced using standard processes, and the modular assembly simplifies manufacturing and maintenance while achieving the required condensation surface area and flow distribution.
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 enhances system reliability by efficiently condensing and collecting water vapor, reducing erosion and icing risks, while maintaining system compactness and reducing weight, thereby improving overall performance and safety.
Implementation Method 1
The body section can condense at least a portion of the fluid flow from a gaseous state into a liquid state
Implementation Method 2
The fluid flow is spun along a swirl vane inlet duct with a swirl vane assembly and thereby separating a liquid portion of the fluid flow from a gas portion of the fluid flow
Data Source
AI summary
A coalescing tube bundle elbow for a water collector includes an inlet end, an outlet end, and a body section fluidly connecting the inlet and outlet ends. The inlet end can receive a fluid flow in an at least partially gaseous state in an incoming direction. The outlet end can discharge the fluid flow in an at least partially liquid state in an outgoing direction. The body section can condense at least a portion of the fluid flow from a gaseous state into a liquid state. The body section includes channels which are defined by channel walls and which extend along the body section from the inlet end to the outlet end, and has a curved profile such that the outgoing direction of the fluid flow is not parallel to the incoming direction of the fluid flow.