Vertical Liquid-Cooled Galley Chiller for Space and Weight Reduction
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Solution Overview
Problem
Conventional refrigeration systems in aircraft galleys are too heavy and occupy excessive space, leading to inefficiencies in heat transfer and condensation management, which complicates the preservation of perishables during flights.
Innovation Solution
A compact, lightweight chilled air distribution system with a vertically oriented cooling unit and interlock mechanism that diverts refrigerant through a bypass loop when carts are removed, utilizing air-to-liquid heat exchangers and flexible hoses for efficient coolant distribution, and incorporating a three-way divert valve for temperature control and automatic condensation drainage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional refrigeration systems are used in aircraft galleys, then perishables can be kept fresh during flight, but the systems are too heavy and occupy excessive space
Solution Approach 1:
The patent employs a liquid-to-air heat exchanger system where chilled liquid (hydraulic/thermal medium) circulates through a closed loop to cool air that then contacts the perishables. This hydraulic thermal transfer approach replaces conventional heavy compression-based refrigeration, achieving weight reduction while maintaining preservation reliability through efficient heat exchange between the chilled liquid and air streams
Solution Approach 2:
The chiller system is divided into separate functional modules: a centralized chilled liquid circulation system, individual air-to-liquid heat exchangers at each galley location, and independent air circulation paths. This segmentation allows the heavy compression equipment to be centralized or removed entirely, with only lightweight heat exchanger components distributed throughout the aircraft, significantly reducing overall system weight while maintaining preservation capability
2Reliability
If conventional refrigeration systems are used in aircraft galleys, then perishables can be kept fresh during flight, but the systems occupy excessive space in the galley
Solution Approach 1:
The liquid-to-air heat exchanger design consolidates thermal transfer functions into compact exchanger assemblies that occupy minimal galley space. The chilled liquid circulates through narrow-bore piping and compact heat exchange surfaces, replacing the bulky evaporators and compressors of conventional systems, thereby preserving galley space while maintaining cooling reliability
Solution Approach 2:
The system transitions from horizontal space-consuming components to a vertically-oriented heat exchanger design that utilizes the vertical dimension within the galley structure. The air-to-liquid exchanger is positioned to extend vertically, allowing chilled air to flow through multiple levels, thereby achieving effective cooling volume with minimal horizontal footprint
3Reliability
If conventional chiller systems are used, then cooling function is provided, but heat transfer efficiency is insufficient and condensation management is complicated
Solution Approach 1:
The liquid-to-air heat exchanger inherently separates the liquid refrigerant circulation from the air cooling medium. Condensation that forms on the chilled liquid piping and heat exchanger surfaces drains naturally through gravity-fed channels integrated into the heat exchanger structure, eliminating the need for complex mechanical condensation removal systems while maintaining effective cooling
Solution Approach 2:
The heat exchanger design incorporates self-draining features where condensation automatically collects and drains through gravity to designated discharge points without requiring pumps, valves, or active control systems. The thermal design also promotes condensation formation at locations where gravity-assisted drainage is most effective, allowing the system to manage its own condensation removal passively
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 system significantly reduces galley space and weight while enhancing heat transfer efficiency, allowing for independent chilling of each cart bay and eliminating the need for air control flaps, thus improving the preservation of perishables and reducing operational costs.
Implementation Method 1
a heat exchanger, where an electric axial (or other) fan blows or sucks air through its matrix around enclosed areas of the storage structure that requires chilling
Implementation Method 2
The chilled liquid is pumped in a closed loop to and from a suitable storage structure... The chilled liquid in some cases are configured as a large centralized system for the whole aircraft
Data Source
AI summary
A chiller for an aircraft galley beverage cart compartment is disclosed wherein a liquid cooled chiller is located in the cart compartment vertically oriented against a back wall. The chiller engages the carts and circulates chilled air efficiently with a reduced footprint, allowing the depth of the cart compartment to be reduced. The unit includes a proportioning valve to control the amount of fluid through the heat exchanger and a distribution block on the post-cooling side to efficiently route the spent refrigerant.