Dual-Loop Thermal Management System to Reduce Aircraft Cooling Weight
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Solution Overview
Problem
Conventional thermal management systems for aircraft and vehicles require separate heat exchangers for components with different temperature requirements, leading to increased weight, volume, and aerodynamic drag, as well as decreased efficiency due to the mixing of hot and cold coolant streams.
Innovation Solution
A thermal management system with a first and second heat exchanger loop, utilizing a compressor and expander to manage temperature differences between components like batteries and electric motors, with a third and fourth heat exchanger using air or liquid fuel to optimize cooling and generate thrust, minimizing the need for multiple heat exchangers and reducing weight and drag.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If separate heat exchangers are used for components with different temperature requirements, then each component can be cooled to its required temperature, but the weight and volume of the cooling system increases
Solution Approach 1:
The patent combines multiple heat exchanger functions into a single integrated heat exchanger that handles both battery cooling and motor cooling in one unit. This merging eliminates the need for separate heat exchangers for each component, directly reducing the overall weight and volume of the cooling system while maintaining the ability to provide appropriate cooling temperatures for each component type.
Solution Approach 2:
The integrated heat exchanger is designed to perform multiple functions simultaneously - cooling batteries at lower temperatures and cooling motors at higher temperatures through a single device. This multi-functional approach allows one heat exchanger to replace what would traditionally require multiple separate units, thereby reducing system weight.
2Temperature
If separate heat exchangers are used for components with different temperature requirements, then each component can be cooled to its required temperature, but the volume of the cooling system increases
Solution Approach 1:
The patent combines multiple heat exchanger functions into a single integrated heat exchanger that handles both battery cooling and motor cooling in one unit. This merging eliminates the need for separate heat exchangers for each component, directly reducing the overall weight and volume of the cooling system while maintaining the ability to provide appropriate cooling temperatures for each component type.
3Device complexity
If hot coolant from different sources is mixed, then the cooling system can operate with fewer components, but the resulting cooler coolant requires a larger heat exchanger to dissipate heat
Solution Approach 1:
The patent segments the cooling process into distinct thermal zones within the single integrated heat exchanger - a first section for cooling batteries at lower temperatures and a second section for cooling motors at higher temperatures. This segmentation allows each component to be cooled at its optimal temperature without mixing coolants, preventing the need for oversized heat exchangers while maintaining low device complexity.
4Temperature
If multiple separate heat exchangers are used, then each component can be cooled independently, but the aerodynamic drag increases
Solution Approach 1:
The patent combines multiple heat exchanger functions into a single integrated heat exchanger that handles both battery cooling and motor cooling in one unit. This merging eliminates the need for separate heat exchangers for each component, directly reducing the overall weight and volume of the cooling system while maintaining the ability to provide appropriate cooling temperatures for each component type.
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 system effectively cools components to their required temperatures while minimizing weight, volume, and aerodynamic drag, and utilizes waste heat to generate thrust, enhancing overall efficiency and reducing energy consumption.
Implementation Method 1
a first working fluid compressor downstream in first working fluid flow of the first heat exchanger and configured to compress the first working fluid
Implementation Method 2
an expander downstream in first working fluid flow of the second heat exchanger, and configured to expand and cool first working fluid and deliver cooled first working fluid to the first heat exchanger
Implementation Method 3
a first heat exchanger configured to exchange heat between a first component and a first working fluid
Implementation Method 4
configured to exchange heat between the first working fluid and a second working fluid
Data Source
AI summary
A thermal management system comprises a first heat exchanger configured to exchange heat between a first component and a first working fluid, a first working fluid compressor downstream in first working fluid flow of the first heat exchanger and configured to compress the first working fluid, a second heat exchanger downstream in first working fluid flow of the compressor and configured to exchange heat between the first working fluid and a second working fluid and an expander downstream in first working fluid flow of the second heat exchanger, and configured to expand and cool first working fluid and deliver cooled first working fluid to the first heat exchanger. The system further comprises a third heat exchanger upstream in second working fluid flow of the second heat exchanger, and configured to exchange heat between a second component and the second working fluid.