Pumped Two-Phase Cooling Loop for Aircraft Electronics Start-Up Heat
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Solution Overview
Problem
Aircraft using hydrogen fueled fuel cells face challenges in efficiently managing heat, particularly during start-up and varying flight phases, due to the high temperature proton exchange membrane fuel cells and the need for effective thermal management systems.
Innovation Solution
The implementation of a pumped two-phase cooling system, which includes an evaporator, condenser, accumulator, and pump system, to efficiently cool heat loads in aircraft electronics, and a dual loop thermal management system to separately control the temperature of high temperature proton exchange membrane fuel cell stacks and lower temperature components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If a conventional thermal management system is used for high temperature proton exchange membrane fuel cells, then the system can manage heat, but the start-up time and energy consumption are excessive
Solution Approach 1:
The thermal management system is divided into two separate loops: a first loop for cooling high temperature components (fuel cell stacks) and a second loop for cooling lower temperature components (electronics, batteries). This segmentation allows each loop to be optimized independently, with the first loop enabling faster start-up of fuel cells while the second loop handles electronics cooling, thereby reducing overall start-up time without excessive complexity
Solution Approach 2:
The system uses different coolant temperatures and flow rates in the two loops to match the thermal requirements of different components. The first loop operates at higher temperatures suitable for fuel cell cooling during start-up, while the second loop operates at lower temperatures for electronics, optimizing thermal management efficiency and reducing start-up time
2Weight of moving object
If a conventional thermal management system is used, then heat can be managed, but the weight and drag of the system are excessive
Solution Approach 1:
By segmenting the thermal management system into two dedicated loops, each component can be sized appropriately for its specific thermal load, avoiding the need for an oversized single system. This reduces the overall weight of heat exchangers, pumps, and piping while maintaining reliable heat management for both high temperature fuel cells and lower temperature electronics
Solution Approach 2:
The thermal management system is designed to serve multiple functions through the two-loop architecture: the first loop provides both cooling during operation and heat extraction during start-up, while the second loop handles electronics cooling and can potentially recover heat. This multi-functionality reduces the need for separate systems, lowering overall weight while maintaining heat management reliability
3Adaptability or versatility
If a single loop thermal management system is used, then the system structure is simpler, but it cannot separately control the temperature of different components
Solution Approach 1:
The system is segmented into two independent thermal loops, each with its own coolant circulation and temperature control. The first loop is dedicated to fuel cell stacks with high temperature requirements, while the second loop serves electronics and batteries with lower temperature requirements. This segmentation provides the adaptability to separately control each component's temperature while keeping the system structure manageable through modular design
4Quantity of substance
If liquid hydrogen storage tanks are used, then hydrogen can be stored, but the extremely low temperatures require specialized thermal management
Solution Approach 1:
The system converts the cold from liquid hydrogen storage into a useful resource by using it for cooling electronics and batteries through the second loop. The evaporative cooling from the liquid hydrogen tanks provides a natural cold source that reduces the energy required for electronics thermal management, turning the challenging low temperature into a beneficial cooling resource
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 solution effectively reduces the time and energy required for start-up of high temperature proton exchange membrane fuel cell stacks, improves heat management efficiency, and reduces the overall weight and drag of thermal management systems.
Implementation Method 1
The evaporator is configured to cool a set of heat loads in an aircraft using a liquid. The liquid forms a vapor in response to cooling the set of heat loads.
Implementation Method 2
The condenser is configured to receive the vapor from the evaporator and cool the vapor in which cooling the vapor forms the liquid.
Data Source
AI summary
An aircraft cooling system comprises an evaporator, condenser, an accumulator, and a pump system. The evaporator is configured to cool a set of heat loads in an aircraft using a liquid. The liquid forms a vapor in response to cooling the set of heat loads. The condenser is configured to receive the vapor from the evaporator and cool the vapor in which cooling the vapor forms the liquid. The accumulator is configured to receive the liquid from the condenser and store the liquid. The pump system is configured to pump the liquid stored in the accumulator to the evaporator.