Thermal Expansion Cooling Valve for Fire-Triggered Actuator Flow
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Solution Overview
Problem
In gas turbine engines, the constant flow of cooling fluid to actuators is unnecessary under normal conditions, leading to increased fuel pump volume requirements and reduced cooling capacity at heat exchangers due to constant heating, and existing temperature-responsive plugs are slow to respond and prone to resolidification, disrupting cooling fluid flow.
Innovation Solution
A cooling fluid valve with a plug and valve housing made from materials with distinct coefficients of thermal expansion, where the housing expands more than the plug upon heating, causing the force fit to be eliminated and allowing rapid flow initiation when exposed to high temperatures, ensuring efficient cooling fluid delivery to actuators during fires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cooling fluid flows constantly to actuators, then actuators are continuously cooled, but fuel pump volume requirements increase and cooling capacity at heat exchangers is reduced
Solution Approach 1:
The valve transitions from constant cooling fluid flow to periodic/conditional flow based on temperature detection. The plug remains closed during normal operation and only opens when fire detection temperature is reached, converting continuous flow into event-driven flow.
Solution Approach 2:
The invention extracts the unnecessary constant cooling function and replaces it with on-demand cooling. By removing the continuous flow requirement and implementing temperature-triggered flow, the system eliminates parasitic fuel consumption while maintaining actuator protection.
2Reliability
If cooling fluid flows constantly to actuators, then actuators are continuously cooled, but cooling capacity at heat exchangers is reduced due to constant heating
Solution Approach 1:
The valve transitions from constant cooling fluid flow to periodic/conditional flow based on temperature detection. The plug remains closed during normal operation and only opens when fire detection temperature is reached, converting continuous flow into event-driven flow.
Solution Approach 2:
The invention converts the harmful effect of constant fuel heating into a beneficial on-demand cooling system. By using temperature-responsive materials that react to fire conditions, the system only activates cooling when actually needed, preventing unnecessary heat exchanger loading.
3Quantity of substance
If an O-ring plug is used to block cooling fluid flow, then flow is blocked under normal conditions, but the plug responds slowly and may resolidify stopping flow
Solution Approach 1:
The invention changes the material parameter from O-ring elastomer to low-melting-point alloy with specific melting temperature (150-250°C). This parameter change enables rapid phase transition from solid to liquid state when fire temperature is detected, achieving fast response without resolidification issues.
Solution Approach 2:
The plug utilizes phase transition from solid to liquid state at a specific temperature range (150-250°C) to rapidly open the flow path. This phase change mechanism provides immediate response to fire conditions and maintains open state as liquid, preventing resolidification that would stop flow.
4Quantity of substance
If a plug is mounted within the actuator housing, then flow blocking is achieved, but response to fire is slow
Solution Approach 1:
The valve actuator portion extends outwardly beyond the housing outer surface, adding a spatial dimension for direct fire exposure. This dimensional change allows the temperature-responsive plug to be positioned in the path of incoming fire, dramatically reducing thermal response time compared to interior mounting.
Solution Approach 2:
The plug is pre-positioned in the flow path at the extended actuator portion, ready to respond immediately when fire temperature is detected. The outward extension ensures the plug is already in the optimal position for rapid fire detection and response, eliminating delays associated with interior mounting.
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 solution enables rapid and reliable initiation of cooling fluid flow to actuators during high-heat situations, reducing parasitic flow and maintaining cooling capacity while minimizing unnecessary fuel usage and heat exchanger heating.
Implementation Method 1
The plug is formed of a material having a first coefficient of thermal expansion. A portion of the valve housing includes the orifice is formed of a material having a second coefficient of thermal expansion. The second coefficient of thermal expansion is higher than the first coefficient of thermal expansion, such that when the actuator portion of the valve is exposed to heat, the force fit may be eliminated as the valve housing expands at greater rate than the plug.
Data Source
AI summary
A cooling fluid valve having an actuator portion extending outwardly beyond an outer surface of an actuator housing. The cooling fluid valve actuator portion includes a plug force fit into an orifice in a valve housing. The plug blocks flow of cooling fluid from a cooling fluid inlet to a cooling fluid outlet. The cooling fluid outlet is connected to communicate cooling fluid to the component. The plug is formed of a material having a first coefficient of thermal expansion. A portion of the valve housing includes the orifice receiving the plug being formed of a material having a second coefficient of thermal expansion with the second coefficient of thermal expansion being higher than the first coefficient of thermal expansion, such that when the actuator portion of the valve is exposed to heat, the force fit may be eliminated as the valve housing expands at greater rate than the plug.