Modular Aircraft Cooling Rack Expansion
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Solution Overview
Problem
Conventional aircraft cooling systems require extensive upgrades and replacements to increase capacity, leading to prolonged aircraft grounding and significant expenses, as they struggle to accommodate increased heat generation from retrofitted improvements and accessories.
Innovation Solution
A modular expandable cooling system featuring a rack for receiving multiple modular cooling units, which utilize ram air and refrigerant circulation to enhance cooling capacity without replacing existing cooling packs, engine bleed systems, or duct networks, allowing for incremental capacity expansion by adding additional modular units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional cooling systems are upgraded to increase cooling capacity, then cooling capacity is improved, but aircraft must be grounded for extended periods and considerable expense is incurred
Solution Approach 1:
The cooling system is divided into modular cooling units that can be independently installed or removed from the rack. Each module contains complete cooling components (compressor, condenser, evaporator, expansion device), allowing incremental capacity increases without replacing entire cooling packs or duct networks, thus avoiding extended aircraft grounding.
Solution Approach 2:
The system transitions from a fixed, monolithic cooling system to a dynamic, reconfigurable modular system. The rack can accommodate varying numbers of cooling modules based on cooling demand, and modules can be added or removed without system shutdown, enabling flexible capacity adjustment while the aircraft remains operational.
2Power
If conventional cooling systems are replaced to accommodate increased heat generation, then cooling capacity is improved, but considerable expense is incurred
Solution Approach 1:
By segmenting the cooling system into standardized modular units that interface with existing duct networks and evaporators, the patent enables incremental capacity expansion through adding individual modules rather than replacing entire cooling packs, engine bleed systems, or duct networks, significantly reducing upgrade costs.
Solution Approach 2:
The modular cooling units are designed with universal interfaces that can connect to existing aircraft cooling infrastructure (duct networks, evaporators). This universality allows the same module design to serve different aircraft types and configurations, reducing development and manufacturing costs through economies of scale.
3Power
If cooling system capacity is increased through traditional methods, then cooling capacity is improved, but cooling packs, engine bleed systems, and duct networks must be replaced
Solution Approach 1:
The cooling system is segmented into self-contained modular units that can be independently added to the rack. Each module integrates all necessary cooling components (compressor, condenser, evaporator, expansion device), eliminating the need to reconfigure existing cooling packs, engine bleed systems, or duct networks when increasing capacity.
Solution Approach 2:
The modular cooling units are designed to nest within a standardized rack structure that interfaces with the existing aircraft cooling infrastructure. The modules can be stacked or arranged in various configurations within the same rack space, allowing capacity expansion without modifying the overall system architecture or replacing existing components.
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
Enables efficient and cost-effective expansion of cooling capacity to manage increased heat loads without grounding the aircraft for extensive upgrades, reducing downtime and expenses by allowing incremental additions of modular cooling units to existing systems.
Implementation Method 1
a condenser mounted in the housing in fluid communication with the ram air inlet having an outlet in fluid communication with the refrigerant outlet
Implementation Method 2
a condenser mounted in the housing in fluid communication with the ram air inlet having an outlet in fluid communication with the refrigerant outlet
Implementation Method 3
an on-board evaporator through which refrigerant circulates to cool a portion of the aircraft
Implementation Method 4
an on-board evaporator through which refrigerant circulates to cool a portion of the aircraft
Implementation Method 5
a compressor mounted in the housing downstream from the condenser having an outlet in fluid communication with the condenser inlet and an inlet
Data Source
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AI summary
A modular expandable cooling system including a rack sized for receiving multiple modular cooling units having a ram air inlet connected to a ram air source. The system also includes a modular cooling unit having a housing for receipt in the rack, a ram air inlet and outlet, and a refrigerant inlet and outlet. The system includes a condenser mounted in the housing in fluid communication with the ram air inlet, a compressor mounted in the housing downstream from the condenser, an accumulator in fluid communication with the compressor inlet.