Patent Publication Number: US-2017350322-A1

Title: Heated starter air valve

Description:
BACKGROUND OF THE DISCLOSURE 
     The subject matter disclosed herein relates to starter air valves and, more particularly, to heated starter air valves. 
     In aircrafts and other similar machines, starter air valves can be provided as parts of engines and may be oriented vertically. Such starter air valves can thus collect water due to condensation and, if the aircraft in which the starter air valve is installed sits overnight in a cold place, the collected water can freeze within the valve body. This frozen water can prevent the starter air valve from opening during start-up operations of the aircraft engines and may cause flight delays or cancellations. 
     One design that has been proposed for addressing the problem of frozen water in starter air valves is that drainage features are incorporated into the valve body. The drainage features can be formed as drain holes and allow collected water to flow through them out of the valve body. As such, the drainage features are capable of preventing the collected water from pooling and then freezing. 
     BRIEF DESCRIPTION OF THE DISCLOSURE 
     According to one aspect of the disclosure, a heated valve is provided and includes a valve body having an inlet, an outlet downstream from the inlet and a valve section fluidly interposed between the inlet and the outlet, a valve element operably disposed within the valve section to assume and move between at least a first position at which fluid communication between the inlet and the outlet is prevented by the valve element and a second position at which the fluid communication is permitted and a heating system. The heating system is in operable communication with at least one of the valve body and the valve element and is configured to melt ice that could prevent movement of the valve element between the first and second positions. 
     In accordance with additional or alternative embodiments, a valve actuator is coupled to the valve element and configured to drive movements thereof. 
     In accordance with additional or alternative embodiments, the valve body is disposable with the inlet above the outlet. 
     In accordance with additional or alternative embodiments, the valve body is substantially cylindrical and the valve element includes a butterfly valve. 
     In accordance with additional or alternative embodiments, the heating system includes a heating element operably disposed within at least the valve body and a power source coupled to and configured to activate the heating element to generate heat. 
     In accordance with additional or alternative embodiments, the valve element includes a valve plate and a drive shaft configured to drive movements of the valve plate and the heating system includes a valve plate heating element disposed to heat the valve plate and a coupling configured to electrically connect the valve plate heating element and the power source during movements of the valve element. 
     In accordance with additional or alternative embodiments, the valve body includes first and second layers and the heating element includes a resistance wire interposed between the first and second layers. 
     In accordance with additional or alternative embodiments, the valve body further includes a seal ring disposable on an interior surface of an innermost one of the first and second layers. 
     According to another aspect of the disclosure, a valve body is provided and includes an inner layer formed to define an inlet, an outlet downstream from the inlet and a valve section fluidly interposed between the inlet and the outlet, an outer layer disposed to surround the inner layer and a heating element operably interposed between the inner and outer layers and configured to generate heat proximate to a valve element operably disposed within the valve section to assume and move between valve closing and valve opening positions. 
     In accordance with additional or alternative embodiments, at least the valve section is annular and the valve element is a butterfly valve. 
     In accordance with additional or alternative embodiments, the heating element includes a resistance wire interposed between the first and second layers. 
     In accordance with additional or alternative embodiments, a seal ring is disposable on an interior surface of an innermost one of the first and second layers. 
     According to yet another aspect of the disclosure, an engine is provided and includes a gas turbine engine section, a starter configured to start the gas turbine engine section and a valve system configured to control airflow into the starter during operations to start the gas turbine engine section. The valve system includes a valve body, a valve element operably disposed within the valve body to assume and move between valve body closing and valve body opening positions, a heating element operably disposed within at least the valve body and a power source coupled to and configured to activate the heating element to generate heat. 
     In accordance with additional or alternative embodiments, a valve actuator is configured to drive movements of the valve element. 
     In accordance with additional or alternative embodiments, the valve body is disposable such that fluid pools on the valve element in the valve body closing position. 
     In accordance with additional or alternative embodiments, a valve element heater is disposed to heat the valve element and a coupling is configured to electrically connect the valve element heater and the power source during movements of the valve element. 
     In accordance with additional or alternative embodiments, the valve body includes first and second layers and the heating element includes a resistance wire interposed between the first and second layers. 
     In accordance with additional or alternative embodiments, the valve body further includes a seal ring disposable on an interior surface of an innermost one of the first and second layers. 
     In accordance with additional or alternative embodiments, the first and second layers and the resistance wire include metallic materials. 
     These and other advantages and features will become more apparent from the following description taken in conjunction with the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The subject matter, which is regarded as the disclosure, is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features, and advantages of the disclosure are apparent from the following detailed description taken in conjunction with the accompanying drawings in which: 
         FIG. 1  is a schematic diagram of an aircraft engine in accordance with embodiments; 
         FIG. 2  is a perspective view of a starter air valve in accordance with embodiments; 
         FIG. 3  is a side view of the starter air valve in an operational mode; 
         FIG. 4  is an axial view of a valve body taken along line  4 - 4  of  FIG. 2 ; 
         FIG. 5  is a circumferential view of the valve body taken along line  5 - 5  of  FIG. 4 ; 
         FIG. 6  is a cutaway side view of the valve body and a heating element in accordance with embodiments; and 
         FIG. 7  is a side view of a valve plate heating element and a coupling in accordance with embodiments. 
     
    
    
     The detailed description explains embodiments of the disclosure, together with advantages and features, by way of example with reference to the drawings. 
     DETAILED DESCRIPTION OF THE DISCLOSURE 
     A problem with the drainage features of starter air valves of aircraft engines is that the drainage features often permit air leakage when the valves are closed. This reduces efficiencies of the engines and their associated system. Thus, as will be described below, a starter air valve is provided in which electric heat is used to melt ice that would otherwise prevent the starter air valve from opening prior to start-up of the engine. Such use of electric heat allows for the starter air valve to not have need for drainage features and so will decrease leakage when the starter air valve is in the closed position thus increasing system efficiency. The use of the electric heat could be applicable and used in any pneumatic valve environment where ice build-up could occur inside the valve and prevent the valve from opening. 
     With reference to  FIG. 1 , an engine  1  is provided for use with an aircraft or another similar machine. The engine includes a gas turbine engine section  2  and a starter  3  which is configured to start the gas turbine engine section  2 . The gas turbine engine section  2  has a compressor that compresses inlet air, a combustor in which the compressed inlet air is mixed with fuel and combusted and a turbine in which high temperature and high pressure fluids produced by the combustion are expanded. The turbine is coupled to a rotor which is turned by the expansion of the high temperature and high pressure fluids and the rotor, in turn, turns the compressor. 
     During start-up operations of the engine  1  and before the turbine is up to speed, the starter  3  is coupled to the gas turbine engine section  2  and thereby turns the rotor and the compressor. Such operation of the starter requires airflow to be modulated by a starter air valve  4  disposed upstream from the starter  3 . In many cases, the starter air valve  4  is oriented substantially vertically within the engine  1  and thus tends to collect water therein due to condensation. This water can freeze if the surrounding air is cold enough (e.g., if the associated aircraft is parked overnight in cold weather) with the resulting ice potentially preventing the starter air valve  4  from opening during engine  1  start-up operations. 
     Thus, with reference to  FIGS. 2 and 3 , a heated valve  10  is provided and may be configured as a heated starter air valve for use in the starter  3  of the engine  1  of  FIG. 1  or in any pneumatic valve environment. In any case, the heated valve  10  includes a valve body  11 , a valve element  12  and a heating system  13 . The valve body  11  has an inlet section  110 , an outlet section  111  downstream from the inlet section  110  and a valve section  112  which is fluidly interposed between the inlet section  110  and the outlet section  111 . The valve element  12  is operably disposable within the valve section  112  to assume and move between at least a first (or closed) position at which fluid communication between the inlet section  110  and the outlet section  111  is prevented by the valve element  12  and a second (or open) position at which the fluid communication between the inlet section  110  and the outlet section  111  is permitted. 
     The heating system  13  is disposable in operable communication with at least one of the valve body  11  and the valve element  12  and is configured to melt ice that could prevent movement of the valve element  12  between the first and second positions. The heating system  13  may include at least a heating element  130  that is operably disposable within at least the valve body  11  and a power source  131 . The power source  131  is coupled to and configured to activate the heating element  130  to generate heat. 
     The power source  131  can be a battery or some other source of electricity that supplies the heating element  131 , such as a resistance wire  132  formed of metallic materials (e.g., copper), with current. This current causes the heating element  130  to heat and this heat is conducted into the valve body  11  or radiated outwardly to generally raise the temperature of the valve  11  in and around at least the valve section  112 . As a result, any ice formed within the valve body  11  is melted so that the valve element  12  can freely move within the valve body  11 . 
     In accordance with embodiments, the valve body  11  may be substantially cylindrical with the inlet section  110 , the outlet section  111  and the valve section being generally annular at least in their respective interior spaces. Here, the valve element  12  may be provided as a butterfly valve including a valve plate  120  and a drive shaft  121 . The drive shaft  121  is coupled with the valve plate  120  and extends through the valve body  11  to a valve actuator  14 , which is coupled to an exterior of the valve body  11 . The valve actuator  14  is configured to drive rotations of the drive shaft  121  about its longitudinal axis such that the drive shaft  121  drives rotational movements of the valve  120 . The rotational movements of the valve plate  120  may be directed such that the valve plate  120  rotates from the first (or closed) position to the second (or open) position and from the second position to the first position. 
     In certain cases, with reference to  FIG. 3 , the valve body  11  may be oriented substantially vertically with the inlet section  110  above the outlet section  111  and the valve section  112 . Thus, when the valve plate  120  occupies the first (or closed) position, water can collect within the valve section  112  and then pool on an upper surface of the valve plate  120 . If this water freezes, the resulting ice can prevent the rotational movements of the valve plate  120  but the activation of the heating element  130  generates heat and thereby prevents such freezing and the blocking of the valve plate  120 . 
     With reference to  FIGS. 4 and 5 , the valve body  11  may include a first layer  1101 , a second layer  1102  and a seal ring  1103 . Of the first and second layers, one would be an inner layer and the other would be an outer layer. For purposes of clarity and brevity, it will be assumed that the first layer  1101  is the inner layer and that an interior surface of the first layer  1101  forms the inlet section  110 , the outlet section  111  and the valve section  112  and is annular. Thus, the second layer  1102  is disposed to surround the inner layer  1101  at a distance such that an annular space  1104  is defined between an exterior surface of the first layer  1101  and an interior surface of the second layer  1102 . The heating element  130  (i.e., the resistance wire  132 ) may be interposed between the first layer  1101  and the second layers  1102  and within the annular space  1004 . In accordance with embodiments, where the heating element  130  is the resistance wire  132 , a diameter or thickness of the heating element  130  may be substantially similar to that of the annular space  1104 . As such, the heating element  130  and the first layer  1101  form an extended contact surface along a substantial entirety of a length of the heating element  130 . The seal ring  1103  may be disposed on the interior surface of the first layer  1101  such that edges of the valve plate  120  register with the seal ring  1103  with the valve plate  120  occupying the first (or closed) position. 
     As shown in  FIG. 5 , where the heating element  130  is the resistance wire  132 , a highly thermally conductive material, such as foamed metallic material, can be charged into the annular space  1104  to take up empty space that is not otherwise occupied by the resistance wire  132 . 
     The first and second layers  1101  and  1102  may be formed of metallic materials or, more generally, of highly thermally conductive materials. The first and second layers  1101  and  1102  may be, but are not required to be, electrically conductive. 
     With reference to  FIG. 6  and, in accordance with further embodiments, the heating element  130  may be disposed in the annular space  1104  at the valve section  112  upstream from the axial location of the valve plate  120  in the first (or closed) position. Where possible, the heating element  130  may also be disposed at the inlet section  110 , at the valve section downstream from the axial location of the valve plate  120  and at the outlet section  112 . 
     With reference to  FIG. 7  and, in accordance with further embodiments in which the valve element  12  is a butterfly valve, the heating system  13  may include a valve plate heating element  133  and a coupling  134 . The valve plate heating element  133  is disposed to heat the valve plate  120  similar to the way the heating element  130  heats the valve body  11 . The coupling  134  is configured to electrically connect the valve plate heating element  133  and the power source  131  during movements of the valve plate  120  and may be provided as a brush ring or another similar feature. 
     While the disclosure is provided in detail in connection with only a limited number of embodiments, it should be readily understood that the disclosure is not limited to such disclosed embodiments. Rather, the disclosure can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the disclosure. Additionally, while various embodiments of the disclosure have been described, it is to be understood that the exemplary embodiment(s) may include only some of the described exemplary aspects. Accordingly, the disclosure is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims.