Fuel-Based Cooling Loop for Engine-Mounted Heat-Sensitive Components

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Solution Overview

Problem

Existing cooling systems for heat-sensitive components in hot gas turbine engines are inadequate, as housing these components in cooler locations adds weight and complexity, necessitating specialized cooling solutions to maintain operational efficiency and safety.

Innovation Solution

A fuel-based cooling system utilizing a boost stage pump, fuel bleed, and cooling plates, with optional thermal valves to manage cooling fluid flow, ensuring efficient heat dissipation and temperature regulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If heat-sensitive components are mounted in cooler engine locations, then components are protected from overheating, but engine weight and complexity increase

Engineering Contradiction:

Improvecomponent temperatureVSAvoidcooling system complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent merges the fuel supply system and cooling system into a single integrated architecture. The fuel system's boost stage pump and pressure regulation mechanisms are shared between fuel delivery and cooling functions, eliminating the need for separate cooling pumps and pressure control systems. This integration directly reduces device complexity while maintaining temperature control for heat-sensitive components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The fuel system components, particularly the boost stage pump and pressure regulator, perform multiple functions: fuel pressurization, cooling fluid circulation, and pressure control for both fuel injection and cooling. This multi-functionality eliminates dedicated cooling system components, reducing overall system complexity and weight while ensuring heat-sensitive components remain protected from overheating.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Temperature

If heat-sensitive components are mounted in cooler engine locations, then components are protected from overheating, but engine weight increases

Engineering Contradiction:

Improvecomponent temperatureVSAvoidengine weight

Core Design Contradiction:

TemperatureVSWeight of moving object

Solution Approach 1:

The patent combines the fuel supply system and cooling system into a single integrated architecture. The fuel system's boost stage pump and pressure regulation mechanisms are shared between fuel delivery and cooling functions, eliminating the need for separate cooling pumps and pressure control systems. This integration directly reduces device complexity while maintaining temperature control for heat-sensitive components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Temperature

If fuel flow rate increases to provide adequate cooling at higher engine speeds, then cooling effectiveness improves, but risk of fuel icing increases

Engineering Contradiction:

Improvecooling effectivenessVSAvoidfuel icing risk

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

The patent implements dynamic adaptation of cooling parameters to engine operating conditions. The pressure regulator dynamically adjusts fuel flow rate and pressure based on real-time engine speed and temperature conditions. At higher engine speeds where cooling demand is greater, the system increases fuel flow while maintaining pressure within safe limits to prevent icing. This dynamic control ensures adequate cooling effectiveness across all operating conditions while eliminating the static risk of fuel icing.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system incorporates feedback control through the pressure regulator that monitors engine operating conditions and adjusts fuel flow rate accordingly. The regulator receives information about engine speed, temperature, and fuel pressure, then modulates the cooling fuel flow to maintain optimal cooling effectiveness while preventing fuel icing. This closed-loop feedback ensures the cooling system adapts automatically to changing conditions without manual intervention.

Inventive Principle:

Principle #23Feedback

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 system provides scalable cooling that matches engine temperature needs, preventing overheating and icing while reducing weight and complexity by using available engine fuel as a cooling medium.

Implementation Method 1

a cooler disposed fluidly between the fuel bleed and the fuel return

Methodology Applied

Scientific EffectHeat transfer: Convection

Implementation Method 2

a boost stage pump and a main stage pump

Methodology Applied

Scientific EffectPumping: Pump

Data Source

PatentUS12473859B1Method and system for cooling of engine mounted components

Publication Date: 2025.11.18 HAMILTON SUNDSTRAND CORP

AI summary

A cooling system includes a fuel supply system and a cooling fuel path. The fuel supply system includes a boost stage pump and a main stage pump, while the cooling fuel path includes a fuel bleed from an outlet of the boost stage pump, a fuel return to an inlet of the boost stage pump, and a cooler disposed fluidly between the fuel bleed and the fuel return.