Perforated Graphite Heat Array for Sealed Aircraft Bay Cooling

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Solution Overview

Problem

Sealed equipment bays in aircraft, which house heat-generating electronic components, face challenges in providing effective cooling to prevent premature failure due to moisture intrusion restrictions.

Innovation Solution

A heat transfer system is manufactured by creating a structural assembly with a heat conducting array, comprising perforated pyrolytic graphite sheets and thermally conductive foam elements, which allows for efficient heat dissipation through a network of thermally conductive members and pressure-sensitive adhesive layers, while maintaining structural integrity and moisture protection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If vents or louvers are used for cooling, then heat dissipation is improved, but moisture intrusion risk increases

Engineering Contradiction:

Improveheat dissipationVSAvoidmoisture intrusion

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

The equipment bay is segmented into sealed and unsealed portions, with the heat-generating components located in the sealed portion and cooling vents positioned in the unsealed portion, allowing differential treatment of different functional zones

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A thermal management system acts as an intermediary between the sealed equipment bay and the external environment, transferring heat from the sealed interior to the external cooling vents through thermally conductive pathways

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If the equipment bay is sealed to prevent moisture intrusion, then moisture protection is improved, but cooling capability deteriorates

Engineering Contradiction:

Improvemoisture protectionVSAvoidcooling capability

Core Design Contradiction:

Object-affected harmful factorsVSTemperature

Solution Approach 1:

The cooling function is extracted from the sealed equipment bay and relocated to external vents, allowing the bay to remain sealed while still providing heat dissipation through external cooling structures

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The natural convection cooling mechanism is replaced with a structured thermal management system that uses thermally conductive pathways and external vents to achieve more controlled and efficient heat transfer

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Temperature

If integrated fans or cooling ducts are added, then cooling capability is improved, but device complexity increases

Engineering Contradiction:

Improvecooling capabilityVSAvoidsystem complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The system utilizes natural convection and thermal conduction through existing structural components (skins, foam core, ribs) to achieve cooling without requiring additional active cooling devices like fans or complex ductwork

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Existing structural components of the equipment bay (skins, foam core, ribs) are made to serve dual functions: providing structural support and facilitating heat transfer, thereby eliminating the need for dedicated cooling structures

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

The system effectively reduces temperature differences by dissipating heat generated by components, achieving a 14% reduction in heat transfer to the lower skin, thereby prolonging equipment lifespan and preventing premature failure.

Implementation Method 1

a heat conducting array, comprising perforated pyrolytic graphite sheets and thermally conductive foam elements, which allows for efficient heat dissipation

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

thermally conductive foam elements, which allows for efficient heat dissipation through a network of thermally conductive members

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS9067287B2Method of manufacturing a heat transfer system for aircraft structures

Publication Date: 2015.06.30 AEROVIRONMENT INC

AI summary

A method of manufacturing a heat transfer system is provided that includes, in one form, preparing a heat conducting array by perforating at least a portion of the heat conducting array, placing the heat conducting array around foam elements, placing a heat conducting spreader along one surface area of the foam elements, placing a lower skin over the heat conducting spreader, placing an upper skin over an opposite surface area of the foam elements to create a structural assembly, and curing the structural assembly. A material of the foam elements flows through the perforated portion of the heat conducting array during the curing step.