Passive Heat Exchanger for Gas Turbine Undercowl Cooling

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Solution Overview

Problem

Gas turbine engines face challenges in cooling undercowl components due to increasing temperatures, which can lead to component failure and increased weight and complexity, especially during engine soak-back when electrical power is required for active cooling systems.

Innovation Solution

A passive heat exchanger system with an evaporator section thermally coupled to the engine component and a condenser section in passive convective flow communication, using a working fluid to transfer heat without the need for electrical power, allowing for efficient cooling of complex surfaces and reducing engine weight.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If an active cooling system with electrical fan is used to cool undercowl components, then the components can be cooled effectively, but the engine weight increases and fuel consumption increases

Engineering Contradiction:

Improveundercowl component temperatureVSAvoidengine weight

Core Design Contradiction:

TemperatureVSWeight of moving object

Solution Approach 1:

The patent replaces the active mechanical cooling system (electrical fan) with a passive heat exchanger system that uses phase change of working fluid and natural convection to transfer heat from undercowl components, eliminating the need for powered mechanical cooling devices and reducing engine weight

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent utilizes phase transition of working fluid (evaporation and condensation) within the heat exchanger to efficiently absorb and transfer heat from undercowl components, providing effective cooling without requiring external power sources or moving parts

Inventive Principle:

Principle #36Phase transitions

2Temperature

If an electrical fan is installed for cooling during engine operation, then component temperatures can be controlled, but aircraft battery size must be increased to power the fan during soak-back

Engineering Contradiction:

Improveundercowl component temperatureVSAvoidaircraft battery size

Core Design Contradiction:

TemperatureVSWeight of stationary object

Solution Approach 1:

The patent replaces the electrical fan-based active cooling system with a passive heat exchanger that operates without external power during both engine operation and soak-back periods, eliminating the need for increased aircraft battery capacity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The passive heat exchanger system is self-regulating, using the temperature differential between the undercowl components and ambient air to drive natural convection and phase change of the working fluid, providing continuous cooling during operation and soak-back without external control or power input

Inventive Principle:

Principle #25Self-service

3Temperature

If undercowl components are positioned at remote locations, then cooling requirements are reduced, but connection components increase and maintenance becomes more complex

Engineering Contradiction:

Improvecomponent temperatureVSAvoidconnection components

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent integrates the heat exchanger directly onto the undercowl components themselves, merging the cooling function with the component structure, thereby eliminating the need for remote positioning and reducing connection components while maintaining effective cooling

Inventive Principle:

Principle #5Merging (Combining)

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 passive heat exchanger effectively manages thermal loads, increases component life-cycle, reduces engine weight, and improves efficiency by providing cooling without electrical power, even during engine soak-back.

Implementation Method 1

The heat exchange surface is configured to be thermally coupled in conductive contact to the component surface

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

a working fluid contained within the evaporator section and the condenser section and configured to passively convect heat from the evaporator section to the condenser section

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS11168583B2Systems and methods for cooling components within a gas turbine engine

Publication Date: 2021.11.09 GENERAL ELECTRIC CO

AI summary

A passive heat exchanger includes an evaporator section including a heat exchange surface formed complementary to a surface of a gas turbine engine component to be cooled. The heat exchange surface is configured to be thermally coupled in conductive contact to the component surface. The heat exchanger further includes a condenser section coupled in passive convective flow communication with the evaporator section, and a working fluid contained within the evaporator section and the condenser section and configured to passively convect heat from the evaporator section to the condenser section.