Aircraft Turbine Cooling Air System with Two-Stage Heat Exchangers
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Solution Overview
Problem
Aircraft turbine engines face inefficiencies and potential damage due to thermal energy generated by components like electronics and fluid supply systems, necessitating effective cooling solutions.
Innovation Solution
A two-stage air-to-air heat exchanger system is implemented, augmented by a fuel-to-air heat exchanger in the core airflow, which utilizes fuel-air efficiencies to cool the airflow before it reaches the air-to-air heat exchangers, providing comprehensive cooling for engine and vehicle components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cooling system is added to remove thermal energy from engine components, then system reliability is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple cooling functions into a unified heat exchanger system that utilizes both core airflow and bypass airflow streams. The heat exchangers are integrated into the existing engine structure, merging thermal management functions with the aerodynamic flow paths to reduce overall system complexity while maintaining reliable cooling capability.
Solution Approach 2:
The heat exchanger system serves multiple functions: it cools engine components, pre-cools bypass air, and utilizes thermal energy from both core and bypass streams. This multi-functionality allows a single system to address multiple thermal management needs, improving reliability without proportionally increasing complexity.
2Temperature
If thermal energy is removed from the airflow, then component cooling effectiveness is improved, but energy efficiency deteriorates
Solution Approach 1:
The patent converts the harmful thermal energy that needs to be removed from engine components into a useful resource by using it to pre-cool the bypass airflow. This heat exchange process transforms waste thermal energy into a beneficial cooling effect, improving overall energy efficiency while achieving the required temperature reduction for component cooling.
Solution Approach 2:
The system changes the temperature parameter of different airflow streams strategically - cooling the core airflow to protect engine components while simultaneously using that cooled air to further cool the bypass stream. This parameter manipulation across multiple streams optimizes the thermal energy distribution and reduces total energy loss.
3Temperature
If a two-stage heat exchanger system is implemented, then cooling effectiveness is improved, but device complexity increases
Solution Approach 1:
The patent implements a nested cooling architecture where the first heat exchanger is positioned to cool core airflow, and the second heat exchanger is positioned in the bypass stream to utilize that cooled air. This nesting of cooling stages within the existing engine flow paths achieves enhanced cooling effectiveness while minimizing additional structural complexity by integrating with rather than adding to the engine architecture.
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 cooling system enhances air temperature reduction and increases the efficiency of the air-to-air cooling system, effectively addressing thermal management issues in turbine engines.
Implementation Method 1
a first heat exchanger arranged in the core engine case and configured to receive a liquid and the core airflow, the first heat exchanger providing heat exchange between the liquid and the core airflow to cool the core airflow
Implementation Method 2
a second heat exchanger arranged in the outer air bypass. The second heat exchanger is fluidly coupled to the first heat exchanger to receive the cooled core airflow, and the second heat exchanger provides heat exchange between the cooled core airflow and the second portion of the airflow to further cool the cooled core airflow
Data Source
AI summary
In one aspect, a turbine engine is provided. The engine includes a fan, a core engine case configured to receive a core airflow, and an inner fan case. An inner air bypass is defined between the core engine case and the inner fan case, and the engine further includes an outer fan case, an outer air bypass defined between the inner fan case and the outer fan case, a first heat exchanger arranged in the core engine case, the first heat exchanger providing heat exchange between the liquid and the core airflow to cool the core airflow, and a second heat exchanger arranged in the outer air bypass. The second heat exchanger is fluidly coupled to the first heat exchanger to receive the cooled core airflow. The second heat exchanger provides heat exchange between cooled core airflow and the second portion of airflow to further cool the cooled core airflow.