Helical Water Extractor for Compact Moisture Separation
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Solution Overview
Problem
Existing aircraft air conditioning systems require large and complex water extractors to collect moisture from engine bleed air, which are costly and difficult to assemble, and do not efficiently utilize space due to the need for increasing flow areas to capture water particles.
Innovation Solution
A water extractor is designed using additive manufacturing to create a single-piece, helically configured component with scuppers in each turn of the helical passageway, allowing for efficient centrifugal collection of moisture without the need for a constantly increasing flow area, reducing size and weight while simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional water extractors use increasing scavenge flow areas to capture water particles, then water collection efficiency is improved, but device size and weight increase
Solution Approach 1:
The patent employs a helical curved path instead of a straight linear path for the scavenge flow. The helical wall creates a curved passage that forces water particles to follow a spiral trajectory, enhancing centrifugal separation effects and improving water collection efficiency without requiring increased flow area, thereby maintaining compact dimensions and reduced weight.
Solution Approach 2:
The invention transitions from a conventional linear flow path to a three-dimensional helical flow path. By adding the rotational dimension through the helical configuration, the extractor achieves superior water separation performance within a compact volume, avoiding the need for larger flow areas that would increase weight.
2Ease of manufacture
If traditional water extractors use multiple pieces brazed, welded, and/or bonded together, then manufacturing flexibility is improved, but assembly complexity and time increase
Solution Approach 1:
The patent integrates the scavenge flow channel, helical wall, and water collection features into a single monolithic component manufactured via additive manufacturing. This merging of multiple traditional components into one unified structure eliminates the need for brazing, welding, or bonding operations, significantly reducing assembly complexity while maintaining manufacturing flexibility through digital design and production.
Solution Approach 2:
The invention utilizes additive manufacturing technology to produce the extractor component, representing a fundamental change in the manufacturing parameter from traditional subtractive or assembly-based methods. This manufacturing approach enables complex helical geometries and internal flow channels to be created as a single piece, eliminating multi-step assembly processes while preserving design flexibility.
3Reliability
If traditional water extractors are made large to account for increasing scavenge flow areas, then water capture capability is improved, but space utilization deteriorates
Solution Approach 1:
The helical curved geometry of the scavenge flow channel enhances water particle separation through centrifugal effects along the curved path. This curved configuration allows the extractor to achieve superior water capture capability within a compact footprint by maximizing the utilization of three-dimensional space rather than requiring extensive linear or planar dimensions.
Solution Approach 2:
By implementing a helical three-dimensional flow path, the extractor achieves efficient water capture within a reduced spatial footprint. The helical configuration utilizes vertical and radial dimensions effectively, allowing compact installation while maintaining enhanced water separation performance that would require larger areas in traditional linear configurations.
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 results in a smaller, lighter, and easier-to-assemble water extractor that effectively captures moisture with reduced material usage and operational costs, enabling more compact installation configurations and improved airflow management.
Implementation Method 1
The helical passageway includes a plurality of turns along a bottom of the body. One of the catchment areas is disposed in each turn of the helical passageway. The scuppers are disposed in the catchment areas and are connected to and extend radially inward from the outer wall.
Data Source
AI summary
A water extractor includes an inlet, an outlet a body, outer wall, inner wall, helical wall, plurality of catchment areas, and scuppers. The body extends between the inlet and the outlet. The inner wall is disposed radially inward from the outer wall and forms a main flow channel through a portion of the body. The helical wall extends between and is connected to the outer wall and the inner wall and forms a helical passageway fluidly connected to the inlet and the outlet. The helical passageway includes a plurality of turns along a bottom of the body. One of the catchment areas is disposed in each turn of the helical passageway. The scuppers are disposed in the catchment areas and are connected to and extend radially inward from the outer wall.