Tri-Heat Exchanger Assembly for Aircraft ECS
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Solution Overview
Problem
Existing heat exchanger assemblies for aircraft environmental control systems are bulky, heavy, prone to leakage, and have discontinuous heat transfer fins that can trap particulates, leading to reliability issues and increased assembly time.
Innovation Solution
A heat exchanger assembly that combines three heat exchanger units into a single assembly, eliminating intermediate flanges and seals, and featuring a continuous ram fin for improved airflow and reduced clogging, with a design that orients hot airflow in the direction of gravity to facilitate water drainage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple heat exchangers are separated and bolted together with intermediate flanges and seals, then the assembly is easier to manufacture and assemble, but the weight increases, volume increases, and reliability decreases due to more leak sources
Solution Approach 1:
The patent merges multiple heat exchanger circuits into a single integrated assembly with continuous fins, eliminating intermediate flanges and seals. This combining approach maintains manufacturing feasibility while significantly improving reliability by removing multiple potential leak sources and creating a more robust structural unit.
2Ease of manufacture
If intermediate flanges and seals are used between adjacent heat exchangers, then the assembly allows modular construction, but the weight increases and the chance of leakage or failure increases
Solution Approach 1:
The patent combines multiple heat exchanger circuits into a single welded assembly, eliminating the need for intermediate flanges and seals. This approach reduces weight by removing redundant connection components while maintaining manufacturing capability through integrated fabrication processes.
3Ease of manufacture
If discontinuous heat transfer fins are used across the assembly, then the fins can be manufactured separately and assembled, but particulates become trapped between adjacent heat exchangers causing clogging
Solution Approach 1:
The patent merges the heat transfer fins into a continuous structure that spans across all heat exchanger circuits. This continuous fin design eliminates gaps where particulates could be trapped, preventing clogging while maintaining manufacturability through integrated fabrication methods.
4Adaptability or versatility
If traditional heat exchanger assembly with multiple separate units is used, then the system can be assembled from standard components, but the overall volume and weight of the system increases
Solution Approach 1:
The patent merges multiple heat exchanger circuits into a single compact integrated assembly, reducing the overall volume by eliminating intermediate spacing, flanges, and seals. The design maintains adaptability to different aircraft ECS configurations while achieving significant space savings through consolidation.
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
This configuration reduces the overall volume and weight of the system, enhances reliability by minimizing leak sources, and simplifies assembly, while improving thermal energy transfer efficiency and reducing the risk of water accumulation and clogging.
Implementation Method 1
heat must be removed from air by the ECS before the air is delivered to the aircraft cabin... heat is dissipated by the ECS into a separate stream of air that flows into the ECS, across heat exchangers in the ECS
Implementation Method 2
air flows into the ECS, across heat exchangers in the ECS... carrying the excess heat with it
Implementation Method 3
continuous heat transfer fins across the assembly... continuous ram fin for improved airflow and reduced clogging
Implementation Method 4
design that orients hot airflow in the direction of gravity to facilitate water drainage
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
A heat exchanger assembly (12) for an aircraft includes a first heat exchanger (18) with a first hot air circuit, a second heat exchanger (16) with a second hot air circuit, a third heat exchanger (14) with a third hot air circuit, and a cold circuit (58). The first heat exchanger (18) is in fluid communication with a source of bleed air from the engine. The second heat exchanger (16) is disposed adjacent to and in fluid communication with the first heat exchanger (18). The third heat exchanger (14) is disposed adjacent to and in fluid communication with the second heat exchanger (16). The first, second, and third heat exchangers (18, 16, 14) are fluidly connected in series. The cold air circuit (58) passes through each of the first, second, and third heat exchangers (18, 16, 14). The first, second, and third heat exchangers (18, 16, 14) are in cross-flow communication with the cold air circuit (58).