Embedded Power Electronics in Aircraft Engine Vanes
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Solution Overview
Problem
Existing electric aircraft engines face challenges in reducing mass and aerodynamic drag while maintaining efficient electrical performance, as conventional inverter housings require additional cooling means that increase energy consumption and limit space utilization.
Innovation Solution
Embedding power electronic components, such as power switches and DC bus bars, within the vanes of the electric aircraft engine's stator stage, which benefits from high air mass flow and heat transfer, eliminating the need for additional cooling systems and optimizing space usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If power electronic components are housed in separate conventional inverter housings, then electrical performance is maintained, but mass and aerodynamic drag increase due to additional cooling means
Solution Approach 1:
The patent merges the power electronic components with the engine structure by embedding them directly into the engine housing or stator assembly. This integration eliminates the need for separate inverter housings and their associated cooling systems, thereby reducing overall mass while utilizing the engine's existing airflow for heat dissipation.
Solution Approach 2:
The engine housing or stator assembly serves multiple functions: it provides structural support, guides airflow for thrust generation, and simultaneously acts as a heat sink for cooling power electronic components. This multi-functionality eliminates dedicated cooling means while maintaining effective thermal management.
2Temperature
If additional cooling means are added to inverter housings, then heat dissipation is improved, but energy consumption increases and space utilization is limited
Solution Approach 1:
The power electronic components utilize the engine's own airflow for cooling. The high-velocity air passing through the engine for thrust generation simultaneously serves as the cooling medium for the embedded power electronics, eliminating the need for separate cooling systems and reducing energy consumption.
3Volume of stationary object
If power electronic components are embedded in vanes, then space utilization is optimized and cooling is enhanced, but manufacturing complexity increases
Solution Approach 1:
The power electronic components are embedded in the vanes during the molding process itself. By preparing the vane mold with appropriate cavities and performing the embedding action during molding, the manufacturing complexity is minimized despite the sophisticated integration required.
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 approach reduces mass and aerodynamic drag, enhances heat dissipation for power electronic components, and maintains or improves electrical performance, leading to a more efficient power electronic system without the need for costly cooling solutions.
Implementation Method 1
at least one power electronic component is embedded in at least one of the plurality of vanes... benefits from high air mass flow and heat transfer
Implementation Method 2
enhances heat dissipation for power electronic components
Data Source
Figure 1
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AI summary
According to the present invention, at least one power electronic component (3a, 3b, 4a, 4b, 5a, 5b, 6, 7, 8) is embedded in at least one of a plurality of vanes (11) of an electric aircraft engine (1). This enables cooling of the at least one power electronic component (in particular MOSFETs of an inverter for driving an electric motor of the electric aircraft engine) without additional air or liquid cooling equipment (such as cooling fins or radiators), thus reducing mass and thermal losses.