Swirl Recovery Vane Heat Exchanger for Open Rotor Thermal Management

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Solution Overview

Problem

Open rotor engines face thermal management challenges due to higher gear ratios and lack of confined bypass cooling air, which traditional heat exchangers introduce drag inefficiencies.

Innovation Solution

Integrate swirl recovery vanes (SRVs) as heat exchangers within the open rotor propulsion system, utilizing a trunnion to pivotally connect to an inner platform, with a heat exchanger that channels bleed air from the compressor section to transfer heat from the vanes to ambient air, reducing the need for air-oil coolers (AOCs) and enhancing heat transfer efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If traditional air-oil coolers (AOCs) are used for thermal management, then heat transfer function is provided, but drag and weight increase

Engineering Contradiction:

Improvethermal management capabilityVSAvoiddrag

Core Design Contradiction:

TemperatureVSObject-generated harmful factors

Solution Approach 1:

The patent combines the heat exchanger function with the swirl recovery vane structure into a single integrated component. The heat exchanger is positioned within the vane assembly, allowing thermal management to occur where airflow is already directed, eliminating the need for separate AOCs and reducing overall drag.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The swirl recovery vane assembly serves multiple functions: it recovers swirl energy from the bypass flow, directs airflow for thrust enhancement, and simultaneously houses the heat exchanger for thermal management. This multi-functionality eliminates the need for dedicated AOC components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Temperature

If traditional air-oil coolers (AOCs) are used for thermal management, then heat transfer function is provided, but weight increases

Engineering Contradiction:

Improvethermal management capabilityVSAvoidweight

Core Design Contradiction:

TemperatureVSWeight of moving object

Solution Approach 1:

The heat exchanger is integrated into the swirl recovery vane assembly, combining thermal management functionality with an existing structural component. This integration eliminates the need for separate AOC hardware, thereby reducing overall system weight.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The swirl recovery vane assembly performs multiple functions including flow direction, swirl recovery, and thermal management through the integrated heat exchanger. By making the vane assembly multi-functional, separate weight-bearing AOC structures are eliminated.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Productivity

If higher gear ratios are used in open rotor engines, then propulsion efficiency is improved, but thermal management challenges increase

Engineering Contradiction:

Improvepropulsion efficiencyVSAvoidthermal management difficulty

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The heat exchanger is positioned within the swirl recovery vane assembly where it可以利用 the high-velocity bypass airflow generated by the open rotor system. This integration allows efficient heat transfer without requiring additional cooling air or complex thermal management systems.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The open rotor bypass airflow, which is already present and high-velocity due to the higher gear ratio operation, is utilized directly by the heat exchanger for cooling. The system uses its own operational airflow to provide thermal management, eliminating the need for separate cooling air supplies.

Inventive Principle:

Principle #25Self-service

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

Reduces drag and weight, decreases fuel burn, and increases thrust specific fuel consumption (TSFC) by eliminating AOCs, while providing anti-icing benefits through heat transfer to the vanes.

Implementation Method 1

the gas channel is adapted to: enable gas to flow in through the gas inlet as cool gas and out through a gas outlet as warm gas; and extend into the body of the vane to enable heat transfer from a heat source within the vane to the cool gas

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentEP4656515A1Thermal management system for gas turbine engine with open propulsor

Publication Date: 2025.12.03 RTX CORP

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AI summary

A swirl recovery vane, SRV, (60) includes a trunnion (70) configured to pivotally connect to an exterior surface (62A) of an inner platform (62) of an SRV structure system (30B). The SRV (60) includes a body extending radially from the trunnion (70) to an unshrouded distal vane tip (64) of the vane (60). The SRV (60) includes a heat exchanger (100) that includes a gas inlet (102) configured to couple a bleed air valve (120) of a compressor section (32) of a gas generator (40) to a gas channel (106). The heat exchanger (100) includes the gas channel (106) adapted to: enable gas to flow into the gas inlet (102) as cool gas and out through a gas outlet (104) as warm gas; and extend into the body of the vane (60) to enable heat transfer from a heat source within the vane (60) to the cool gas. The heat exchanger (100) includes the gas outlet (104) configured to output the warm gas from the channel (106) to an ambient environment (28) outside of the vane (60).