Overlapping Heat Exchanger Modules for Intake Air Precooling

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Solution Overview

Problem

Existing propulsion systems face inefficiencies in thrust performance due to temperature limitations, leading to suboptimal transitions between engine modes, particularly in turbomachinery and Ramjet operations, which can result in insufficient thrust for acceleration.

Innovation Solution

A heat exchanger arrangement with modular, overlapping heat exchanger modules centered along the engine's longitudinal axis, allowing independent modulation of heat transfer medium flow, reducing air temperature, and optimizing transitions between engine modes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If precooling is implemented to control intake air temperature, then transition point to higher Mach number is enabled and engine flexibility is improved, but device complexity increases due to additional heat exchanger components

Engineering Contradiction:

Improveengine flexibilityVSAvoidheat exchanger arrangement

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The heat exchanger arrangement is divided into multiple modular heat exchanger modules that can be independently configured and positioned along the engine longitudinal axis. This segmentation allows the system to achieve complex cooling functions while maintaining modular simplicity and ease of integration into existing engine architectures.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The heat exchanger modules are arranged concentrically around the engine longitudinal axis, with inner modules nested within the space defined by outer modules. This nested configuration maximizes the use of available engine volume while minimizing overall footprint, effectively hiding the complexity within a compact arrangement.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Temperature

If multiple heat exchanger modules are arranged along the longitudinal axis, then cooling effectiveness is improved, but the overall engine length increases

Engineering Contradiction:

Improveair temperatureVSAvoidengine length

Core Design Contradiction:

TemperatureVSLength of moving object

Solution Approach 1:

Instead of arranging heat exchanger modules solely in a linear sequence along the longitudinal axis, the patent introduces a radial dimension by positioning modules concentrically around the axis. This multi-dimensional arrangement allows multiple cooling stages to be packed into a compact volume, significantly reducing the effective engine length while maintaining comprehensive cooling capability.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Power

If heat exchanger modules are positioned to maximize cooling, then thrust performance is improved, but airframe integration becomes more difficult

Engineering Contradiction:

Improvethrust performanceVSAvoidairframe integration

Core Design Contradiction:

PowerVSEase of manufacture

Solution Approach 1:

The heat exchanger modules are designed with universal mounting interfaces and standardized configurations that allow them to be integrated into various engine types and airframe designs. This modularity enables the same cooling system architecture to serve multiple applications, simplifying manufacturing and integration while maintaining optimal cooling performance for thrust enhancement.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

Enhances engine flexibility and efficiency by managing temperature profiles, enabling higher Mach number operations and improved thrust performance, particularly in hot environmental conditions, with reduced tip clearance losses and better airframe integration.

Implementation Method 1

a heat exchanger arrangement arranged downstream of the air intake arrangement, configured to cool the air

Methodology Applied

Scientific EffectHeat exchange: Heat Exchanger

Implementation Method 2

providing for heat exchange between the air and a heat transfer medium

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

heat transfer medium flowing through the heat exchanger modules

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS12516631B2Gas turbine engine having a heat exchanger arrangement for heating or cooling a fuel

Publication Date: 2026.01.06 HONEYWELL AEROSPACE US LLC

AI summary

An engine comprises an air intake arrangement configured to receive air; a heat exchanger arrangement arranged downstream of the air intake arrangement, configured to cool the air, and comprising a plurality of heat exchanger modules; and one or more turbomachinery components configured to receive cooled air from the heat exchanger arrangement. The plurality of heat exchanger modules are arranged to be generally centred on and to be arranged along a longitudinal axis of the engine. At least one of the plurality of heat exchanger modules is arranged to at least partially overlap with at least one other one of the plurality of heat exchanger modules relative to the longitudinal axis of the engine.