ECS Dual Entry Ram Inlet Plenum for Aircraft Cooling
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Solution Overview
Problem
Existing aircraft environmental control systems face challenges in efficiently cooling compressed air while minimizing weight, volume, and the risk of water accumulation on heat exchanger fins, which can lead to functionality issues and failure.
Innovation Solution
A heat exchanger assembly with a combined plenum system that integrates three heat exchangers into a single unit, eliminating intermediate flanges and seals, and orienting airflow in the same direction as gravity to facilitate water drainage, thereby reducing the risk of water accumulation and improving reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If multiple heat exchangers are integrated into a single unit with combined plenum, then weight and volume of the system are reduced, but manufacturing complexity increases
Solution Approach 1:
The patent combines multiple heat exchangers (primary heat exchanger, secondary heat exchanger, and tertiary heat exchanger) into a single integrated heat exchanger assembly with a common plenum structure. This merging eliminates the need for separate mounting brackets, fasteners, and intermediate connections, thereby reducing overall weight and volume while consolidating manufacturing into a single integrated component
2Reliability
If intermediate flanges and seals are eliminated through integration, then leak sources are minimized and reliability improves, but manufacturing precision requirements increase
Solution Approach 1:
The integration of multiple heat exchangers into a single assembly with a common plenum eliminates intermediate flanges and seals that would otherwise create potential leak paths. By consolidating the thermal exchange functions into one integrated structure, the patent removes connection interfaces between separate components, thereby improving reliability while managing manufacturing precision through unified construction
3Reliability
If airflow is oriented in the same direction as gravity, then water drainage is facilitated and water accumulation is reduced, but system design complexity increases
Solution Approach 1:
The patent orients the airflow path within the heat exchanger assembly such that the direction of airflow coincides with the direction of gravity. This equipotential alignment allows condensed water to naturally drain along with the airflow without requiring additional drainage components, pumps, or complex routing, thereby facilitating water removal while maintaining simple system architecture
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 reduces the overall weight and volume of the environmental control system, enhances reliability by minimizing leak sources and water accumulation, and improves thermal energy transfer efficiency while maintaining aircraft cabin comfort.
Implementation Method 1
heat must be removed from air by the ECS before the air is delivered to the aircraft cabin. As heat is removed from the air, it is dissipated by the ECS into a separate stream of air that flows into the ECS, across heat exchangers in the ECS
Implementation Method 2
The first stream of air and the second stream of air are combined into a mixed air stream that is directed to an outlet of the plenum that is fluidly connected to an inlet of the heat exchanger assembly
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
An environmental control system of an aircraft with a power turbine includes a heat exchanger (12) and a plenum (28) attached to and in fluid communication with the heat exchanger (12). The plenum (28) includes a housing (108) with a first inlet (110) fluidly connected to the power turbine, a second inlet (112) fluidly connected to a source of ram air, and an outlet (114) fluidly connected to the heat exchanger (12).