Heat exchanger assembly

A heat exchanger assembly includes an outlet header having a first side panel, a second side panel, and a front panel. The first side panel has a first side panel first portion, a first side panel second portion, and a first side panel arcuate portion. The second side panel has a second side panel first portion, a second side panel second portion, and a second side panel arcuate portion. The front panel extends between the first side panel first end and the second side panel first end. The front panel includes a front panel first end that abuts the first side panel first end and a front panel second end that abuts the second side panel first end.

BACKGROUND

Exemplary embodiments pertain to the art of heat exchanger assemblies.

An aircraft cabin may receive a flow of conditioned air from an environmental control system. The environmental control system includes a heat exchanger that conditions air that is to be provided to the aircraft cabin. Transient operating conditions of the aircraft may induce thermal stresses in various sections of the heat exchanger. Accordingly, it is desirable to provide a more robust heat exchanger for an aircraft environmental control system.

BRIEF DESCRIPTION

Disclosed is a heat exchanger assembly for an environmental control system. The heat exchanger assembly includes an inlet header, a primary heat exchanger, and an outlet header. The inlet header is arranged to receive a first fluid that flows along a first axis. The primary heat exchanger is arranged to receive a second fluid that flows along a second axis that is disposed transverse to the first axis. The primary heat exchanger is arranged such that the first fluid flows through the primary heat exchanger along the first axis. The outlet header is operatively connected to the primary heat exchanger and arranged to exhaust the first fluid. The outlet header includes a first side panel and a second side panel. The first side panel has a first side panel first portion, a first side panel second portion, and a first side panel arcuate portion extending between the first side panel first portion and the first side panel second portion along the first axis. The second side panel is spaced apart from the first side panel. The second side panel has a second side panel first portion, a second side panel second portion, and a second side panel arcuate portion extending between the second side panel first portion and the second side panel second portion.

In addition to one or more of the features described herein, a first width is measured between the first side panel first portion and the second side panel first portion, a second width is measured between the first side panel second portion and the second side panel second portion, and a third width is measured between the first side panel arcuate portion and the second side panel arcuate portion.

In addition to one or more of the features described herein, the third width is greater than at least one of the first width and the second width.

In addition to one or more of the features described herein, the first side panel first portion, the first side panel second portion, and the first side panel arcuate portion extends from a first side panel first end towards a first side panel second end along the second axis.

In addition to one or more of the features described herein, the first side panel first portion and the first side panel second portion are disposed parallel to the first axis and the first side panel arcuate portion is disposed in a nonparallel relationship with the first axis.

In addition to one or more of the features described herein, the second side panel first portion, the second side panel second portion, and the second side panel arcuate portion extends from a second side panel first end towards a second side panel second end along the second axis.

In addition to one or more of the features described herein, the second side panel first portion and the first side panel second portion are disposed parallel to the first axis and the second side panel arcuate portion is disposed in a nonparallel relationship with the first axis.

In addition to one or more of the features described herein, a front panel extending between a front panel first end and a front panel second end, wherein the front panel first end is connected to the first side panel first end and the front panel second end is connected to the second side panel first end.

In addition to one or more of the features described herein, the front panel first end and the first side panel first end define a first arcuate corner of the outlet header.

In addition to one or more of the features described herein, the front panel second end and the second side panel first end define a second arcuate corner of the outlet header.

In addition to one or more of the features described herein, a first side panel extension extends from an end of the first side panel arcuate portion towards the first side panel second end.

In addition to one or more of the features described herein, a rear panel disposed opposite the front panel and extending between the first side panel second end and the second side panel second end.

In addition to one or more of the features described herein, the front panel, the rear panel, the first side panel, and the second side panel define a first outlet.

In addition to one or more of the features described herein, a second outlet separated from the first outlet by the rear panel.

In addition to one or more of the features described herein, a secondary heat exchanger operatively connected to the primary heat exchanger and the inlet header, the secondary heat exchanger arranged to receive the second fluid along the second axis and is arranged such that first fluid flows through the secondary heat exchanger in a direction that is disposed substantially parallel to the second axis.

Also disclosed is a heat exchanger assembly. The heat exchanger assembly includes an outlet header having a first outlet and a second outlet spaced apart from the first outlet. The outlet header includes a first side panel, a second side panel, and a front panel. The first side panel has a first side panel first portion, a first side panel second portion, and a first side panel arcuate portion extending between the first side panel first portion and the first side panel second portion along a first axis. Each first side panel portion extends from a first side panel first end towards a first side panel second end along a second axis. The second side panel has a second side panel first portion, a second side panel second portion, and a second side panel arcuate portion extending between the second side panel first portion and the second side panel second portion along the first axis. Each second side panel portion extends from a second side panel first end towards a second side panel second end along the second axis. The front panel extends between the first side panel first end and the second side panel first end.

In addition to one or more of the features described herein, the front panel includes a front panel first end that abuts the first side panel first end and a front panel second end that abuts the second side panel first end.

In addition to one or more of the features described herein, the front panel first end includes a first end first portion that is disposed parallel to the first side panel first portion, a first end second portion that is disposed parallel to the first side panel second portion, and a first end arcuate portion extends between the first end first portion and the first end second portion, the first end arcuate portion abuts the first side panel arcuate portion to define a first arcuate corner.

In addition to one or more of the features described herein, the front panel second end includes a second end first portion that is disposed parallel to the second side panel first portion, a second end second portion that is disposed parallel to the second side panel second portion, and a second end arcuate portion extends between the second end first portion and the second end second portion, the second end arcuate portion abuts the second side panel arcuate portion to define a second arcuate corner.

In addition to one or more of the features described herein, a rear panel extending between the first side panel second end and the second side panel second end and separating the first outlet from the second outlet.

DETAILED DESCRIPTION

An aircraft may have a cabin that is provided with environmental control system. The environmental control system is arranged to provide conditioned air to the cabin. The environmental control system is arranged to receive external air such as a ram air or air bled from a gas turbine engine of the aircraft that is used by a heat exchanger assembly10, as shown inFIG. 1, to condition a fluid, such as air, that is provided to the cabin or other components of the aircraft. Herein, the term “condition” is intended to mean that a fluid that passes through the heat exchanger assembly may have its temperature, pressure, or density either increased, decreased, or maintained.

Referring toFIG. 1, the heat exchanger assembly10includes an inlet header20, a dual heat exchanger22, and an outlet header24.

The inlet header20is arranged to receive a first fluid30that flows along a first axis32. The inlet header20may be operatively connected to a ram air inlet duct such that the first fluid30is ram air. The inlet header20is arranged to direct the first fluid30towards the dual heat exchanger22, such that the first fluid30cools a fluid that flows within or through the dual heat exchanger22.

The dual heat exchanger22is operatively connected to and is disposed between the inlet header20and the outlet header24. The first fluid30flows through the dual heat exchanger22along the first axis32. The flow of the first fluid30through the dual heat exchanger22cools a second fluid34that flows through the dual heat exchanger22along, or substantially parallel to, a second axis36that is disposed substantially transverse to the first axis32.

The dual heat exchanger22includes a primary heat exchanger40and a secondary heat exchanger42that is operatively connected to the primary heat exchanger40. The primary heat exchanger40is operatively connected to the outlet header24. The primary heat exchanger40is arranged to receive and cool the second fluid34that flows along the second axis36. The second fluid34flows through the primary heat exchanger40towards an air cycle machine and is then provided to the secondary heat exchanger42.

The secondary heat exchanger42is operatively connected primary heat exchanger40and the inlet header20. The secondary heat exchanger42is arranged to receive and cool the second fluid34that flows in a direction that is disposed substantially parallel to the second axis36. In such an arrangement, the first fluid30passes through the secondary heat exchanger42and the primary heat exchanger40along the first axis32and cools the second fluid34that flows through the primary heat exchanger40and the secondary heat exchanger42along the second axis36. The first fluid30is exhausted from the heat exchanger assembly10through the outlet header24along the first axis32.

Referring toFIGS. 1-3, the outlet header24is operatively connected to at least one of the primary heat exchanger40and the secondary heat exchanger42of the dual heat exchanger22. The outlet header24is arranged as a dual outlet header having a first outlet50and a second outlet52that is spaced apart from the first outlet50. The heat exchanger assembly10is arranged to selectively enable the first fluid30to be exhausted through the first outlet50, the second outlet52or both of the first outlet50and the second outlet52along the first axis32. The outlet header24includes a first side panel60, a second side panel62, a front panel64, and a rear panel66.

The first side panel60extends between a first side panel proximal end70that is operatively connected to the primary heat exchanger40towards a first side panel distal end72that at least partially defines the first outlet50along the first axis32. The first side panel60extends between a first side panel first end74that is operatively connected to the front panel64towards a first side panel second end76that is disposed proximate the rear panel66. The first side panel60may have a height measured between the first side panel proximal end70and the first side panel distal end72between 8.69 inches (22.07 cm) and 8.82 inches (22.40 cm). The first side panel60may have a length measured between the first side panel first end74and the first side panel second end76of about 29.17 inches (74.09 cm).

The first side panel60includes a first side panel first portion80, a first side panel second portion82, and a first side panel arcuate portion84that extends between the first side panel first portion80and the first side panel second portion82. The first side panel first portion80extends from the first side panel proximal end70towards an end of the first side panel arcuate portion84along the first axis32. The first side panel first portion80is disposed generally parallel to the first axis32. The first side panel first portion80also extends from the first side panel first end74towards the first side panel second end76along the second axis36.

The first side panel second portion82extends from another end of the first side panel arcuate portion84towards the first side panel distal end72along the first axis32. The first side panel second portion82is disposed generally parallel to the first axis32.

The first side panel arcuate portion84extends between the first side panel first portion80and the first side panel second portion82along the first axis32. The first side panel arcuate portion84is disposed in a nonparallel relationship with the first axis32. The first side panel arcuate portion84causes the first side panel60to be curved or have a general c-shape. The first side panel arcuate portion84may have a radius of curvature such that at least a portion of the first side panel arcuate portion84bows or extends away from the first axis32and the first side panel first portion80and the first side panel second portion82. The first side panel arcuate portion84may have a radius of curvature measured from a center or centroid of the inlet header20is between 6.36 inches (16.15 cm) and 6.75 inches (17.14 cm). A maximum distance measured between a peak or apex of the first side panel arcuate portion84and the first side panel first portion80and the first side panel second portion82is between 0.55 inches (1.39 cm) and 0.61 inches (1.55 cm). A maximum distance measured between a peak or apex of the first side panel arcuate portion84and the center or centroid of the inlet header20is about 6.13 inches (15.57 cm).

The first side panel60includes a first side panel extension86that extends from an end of the first side panel arcuate portion84towards the first side panel second end76. The first side panel extension86acts as a transition to taper the first side panel arcuate portion84towards a substantially parallel relationship with the first axis32, the first side panel first portion80, and the first side panel second portion82.

The second side panel62is disposed opposite the first side panel60. The second side panel62extends between a second side panel proximal end90that is operatively connected to the primary heat exchanger40towards a second side panel distal end92that at least partially defines the first outlet50along the first axis32. The second side panel62extends between a second side panel first end94that is operatively connected to the front panel64towards a second side panel second end96that is disposed proximate the rear panel66. The second side panel62may have a height measured between the second side panel proximal end90and the second side panel distal end92between 8.69 inches (22.07 cm) and 8.82 inches (22.40 cm). The second side panel62may have a length measured between the second side panel first end94and the second side panel second end96of about 29.17 inches (74.09 cm).

The second side panel62includes a second side panel first portion100, a second side panel second portion102, and a second side panel arcuate portion104that extends between the second side panel first portion100and the second side panel second portion102. The second side panel first portion100extends from the second side panel proximal end90towards an end of the second side panel arcuate portion104along the first axis32. The second side panel first portion100is disposed generally parallel to the first axis32. The second side panel first portion100also extends from the second side panel first end94towards the second side panel second end96along the second axis36. A distance measured between the first side panel first portion80or the first side panel second portion82and the second side panel first portion100or the second side panel second portion102is about 12.60 inches (32.00 cm).

The second side panel second portion102extends from another end of the second side panel arcuate portion104towards the second side panel distal end92along the first axis32. The second side panel second portion102is disposed generally parallel to the first axis32.

The second side panel arcuate portion104extends between the second side panel first portion100and the second side panel second portion102along the first axis32. The second side panel arcuate portion104is disposed in a nonparallel relationship with the first axis32. The second side panel arcuate portion104causes the second side panel62to be curved or have a general c-shape. The second side panel arcuate portion104may have a radius of curvature such that at least a portion of the second side panel arcuate portion104bows or extends away from the first axis32and the second side panel first portion100and the second side panel second portion102. The second side panel arcuate portion104may have a radius of curvature measured from a center or centroid of the inlet header20is between 6.36 inches (16.15 cm) and 6.75 inches (17.14 cm). A maximum distance measured between a peak or apex of the second side panel arcuate portion104and the second side panel first portion100and the second side panel second portion102is between 0.55 inches (1.39 cm) and 0.61 inches (1.55 cm). A maximum distance measured between a peak or apex of the second side panel arcuate portion104and the center or centroid of the inlet header20is about 6.13 inches (15.57 cm).

The second side panel62includes a second side panel extension106that extends from an end of the second side panel arcuate portion104towards the second side panel second end96. The second side panel extension106acts as a transition to taper the second side panel arcuate portion104towards a substantially parallel relationship with the first axis32, the second side panel first portion100, and the second side panel second portion102.

A plurality of tie rods108extend between the first side panel60and the second side panel62. The plurality of tie rods108may extend between the first side panel second portion82and the second side panel second portion102. At least one tie rod of the plurality of tie rods108is disposed proximate and extends between the first side panel second end76and the second side panel second end96and is located proximate the rear panel66.

Referring toFIG. 4, a first width, w1, is measured between the first side panel first portion80and the second side panel first portion100. A second width, w2, is measured between the first side panel second portion82and the second side panel second portion102. The first width, w1, is substantially equal to the second width, w2. A third width, w3, is measured between the first side panel arcuate portion84and the second side panel arcuate portion104. The third width, w3, is greater than at least one of the first width, w1, and the second width, w2.

Referring toFIGS. 2-4, the front panel64and is operatively connected to the first side panel60and the second side panel62. The front panel64extends between a front panel first end110and a front panel second end112. The front panel64is disposed generally parallel to the first axis32and is disposed generally perpendicular to the second axis36.

The front panel first end110is disposed proximate the first side panel first end74and extends between the first side panel proximal end70and the first side panel distal end72. The front panel first end110is connected to or abuts the first side panel first end74. The front panel first end110has a contour that matches the contour of the first side panel60, in at least one embodiment.

The front panel first end110includes a first end first portion120, a first end second portion122, and a first end arcuate portion124that extends between the first end first portion120and the first end second portion122. The first end first portion120is disposed parallel to and is operatively connected to the first side panel first portion80. The first end second portion122is disposed parallel to and is operatively connected to the first side panel second portion82. The first end arcuate portion124extends between the first end first portion120and the first end second portion122. The first end arcuate portion124abuts the first side panel arcuate portion84to define a first arcuate corner126of the outlet header24.

The front panel second end112is disposed proximate the second side panel first end94and extends between the second side panel proximal end90and the second side panel distal end92. The front panel second end112is connected to or abuts the second side panel first end94. The front panel second end112has a contour that matches the contour of the second side panel62, in at least one embodiment.

The front panel second end112includes a second end first portion130, a second end second portion132, and a second end arcuate portion134that extends between the second end first portion130and the second end second portion132. The second end first portion130is disposed parallel to and is operatively connected to the second side panel first portion100. The second end second portion132is disposed parallel to and is operatively connected to the second side panel second portion102. The second end arcuate portion134extends between the second end first portion130and the second end second portion132. The second end arcuate portion134abuts the second side panel arcuate portion104to define a second arcuate corner136of the outlet header24.

The first side panel arcuate portion84of the first side panel60, the first arcuate corner126, the second side panel arcuate portion104of the second side panel62, and the second arcuate corner136provide thermal stress reductions for the outlet header24. The thermal stress reductions reduce field issues of the heat exchanger assembly10by inhibiting or reducing the potential of stress crack formation to improve part life of the outlet header24of the heat exchanger assembly10.

The rear panel66is disposed opposite the front panel64. The rear panel66is disposed substantially nonparallel and non-perpendicular to the front panel64. The rear panel66extends between the first side panel second end76and the second side panel second end96. Distal ends of the first side panel60, the second side panel62, the front panel64, and the rear panel66define the first outlet50.

The rear panel66includes a rear panel proximal end140and a rear panel distal end142. The rear panel proximal end140is disposed proximate and extends between the first side panel proximal end70and the second side panel proximal end90. The rear panel distal end142is disposed proximate and extends between the first side panel distal end72and the second side panel distal end92. The rear panel66is angled relative to the front panel64such that the rear panel distal end142is disposed closer to the front panel64than the rear panel proximal end140.

The rear panel66includes a rear panel arcuate portion144that extends between the rear panel proximal end140and the rear panel distal end142. The rear panel arcuate portion144is configured as a bulge, a bowed portion, or a curved portion that curves towards a portion146of the outlet header24that defines the second outlet. Furthermore, the rear panel66separates the first outlet50from the second outlet52.