Aircraft Fuel Cell Cooling Circuit Redundancy
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Solution Overview
Problem
Current fuel cell cooling systems for aircraft face inefficiencies in thermal management, particularly in reducing aerodynamic drag and fuel consumption during flight, and lack redundancy for continuous cooling operation.
Innovation Solution
A dual cooling circuit system thermally couples two fuel cells, allowing for redundant cooling and optimal energy distribution, with heat exchangers integrated into the aircraft's outer skin and utilizing ambient air or cooling ribs for heat transfer, and an optional third heat exchanger for heating fuel, enabling efficient waste heat utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional cooling system with separate cooling circuits for each fuel cell is used, then each fuel cell can be cooled independently, but the system lacks redundancy and continuous cooling capability when one circuit fails
Solution Approach 1:
The patent merges the two separate cooling circuits into a single integrated cooling circuit that can serve both fuel cells. The cooling circuit includes a pump, heat exchangers, and thermal management components that are shared between the first and second fuel cells, allowing one circuit to provide redundant cooling capability while reducing overall system complexity compared to fully independent circuits.
2Temperature
If ambient air flow is used for cooling during flight, then heat dissipation is effective, but aerodynamic drag and fuel consumption increase
Solution Approach 1:
The system uses the aircraft's own motion through the air to provide cooling. The heat exchangers are positioned to utilize the natural airflow generated by the aircraft's forward motion during flight, eliminating the need for additional fans or pumps that would consume energy. The cooling system serves itself by harnessing the aerodynamic environment already present during aircraft operation.
Solution Approach 2:
The cooling system adapts to different operational phases of the aircraft. During ground operation, the system can use active cooling with fans or ground-based air flow. During flight, it dynamically switches to passive cooling that utilizes the high-velocity ambient air flow naturally encountered during aircraft motion, optimizing cooling efficiency while minimizing energy consumption in each phase.
3Loss of energy
If waste heat from fuel cells is not utilized, then cooling requirements are simplified, but thermal energy is wasted and overall system efficiency decreases
Solution Approach 1:
The patent converts the harmful waste heat generated by the fuel cells into a beneficial resource. The heat exchangers in the cooling circuit capture thermal energy that would otherwise be discarded and transfer it to ambient air or other heat sinks. This approach transforms the cooling requirement from a purely parasitic load into an opportunity for energy recovery and utilization, improving overall system efficiency while managing thermal loads.
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 ensures effective and efficient cooling of fuel cells during flight without additional ambient air flow, reducing aerodynamic drag and fuel consumption, while providing redundancy for continuous operation and efficient waste heat management.
Implementation Method 1
a first cooling circuit (14) which is thermally coupled to a first fuel cell (16), in order to remove thermal energy generated by the first fuel cell (16) during operation from the first fuel cell (16)
Implementation Method 2
The first heat exchanger (20) is configured in the form of an outer-skin heat exchanger integrated into an outer skin of the aircraft and is provided with a plurality of cooling ribs on an outer surface facing away from an interior of the aircraft
Implementation Method 3
The first heat exchanger (20) is adapted to transfer thermal energy, removed from the first fuel cell (16) via the first cooling circuit (14), to the aircraft surroundings
Implementation Method 4
The first heat exchanger (20) is provided with a plurality of cooling ribs on an outer surface facing away from an interior of the aircraft
Data Source
AI summary
A system for cooling an aircraft fuel cell system comprising a first cooling circuit thermally coupled to a first fuel cell, to remove thermal energy generated by the first fuel cell during operation from the first fuel cell, and a first heat exchanger arranged in the first cooling circuit and adapted to transfer thermal energy, removed from the first fuel cell via the first cooling circuit, to the aircraft surroundings. The system comprises a second cooling circuit thermally coupled to a second fuel cell, to remove thermal energy generated by the second fuel cell during operation from the second fuel cell, and a second heat exchanger arranged in the second cooling circuit and adapted to transfer thermal energy, removed from the second fuel cell via the second cooling circuit, to the aircraft surroundings. The first cooling circuit is thermally couplable to the second cooling circuit.