Patent Description:
Electronic components are utilized in a wide variety of applications including for controlling operations of components or systems or for the supplying of heat, light, or power. For example, in an aircraft environment, electronic components or avionics can be utilized to control the various equipment and operations for flying the aircraft. The electronic components can be stored in a chassis, such as for protecting the avionics from environmental exposure. Electronic components can also generate heat during operation. <CIT> discloses a thermal management system for cooling a heat source onboard an aircraft that has a frame and a skin coupled to the frame such that the skin has a first segment and a second segment includes a first network of heat pipes coupled in conductive heat transfer with the heat source and the first segment of skin. <CIT> discloses a cooling apparatus that includes at least one printed circuit board having opposed major surfaces and a pulsating heat pipe having at least a portion that is positioned to either extend along and proximate to one of the major surfaces or be embedded within the printed circuit board. <CIT> discloses a method and apparatus for radiative heat transfer augmentation for aviation electronic equipment cooled by forced and/or natural convection. <CIT> discloses a cooling system for expelling heat from a heat source located in the interior of an aircraft to a heat reducer, with a piping system sealed against the surrounding atmosphere which is thermally coupled to a heat intake section with the heat source and to a heat output section with the heat reducer.

Claim <NUM> defines a thermal management system. In the following, apparatus and/or methods referred to as embodiments that nevertheless do not fall within the scope of the claims should be understood as examples useful for understanding the invention. In one aspect, the disclosure relates to an aircraft. The aircraft includes at least one of a fuselage, a wing, a skin, or a support structure, an avionics unit adapted to store at least one heat generating component, a first interface operably coupled to the avionics unit and thermally coupled to the at least one heat generating component, and a plurality of heat pipes, wherein a first end of the plurality of heat pipes is coupled to the first interface, defining a hot interface, and a second end of the heat pipes is coupled to the at least one of the fuselage, the wing, the skin, or the support structure.

In another aspect, the disclosure relates to a thermal management system. The thermal management system includes an avionics unit defining an interior configured to house at least one heat generating component, and a first plurality of heat pipes, wherein a first end of the first plurality of heat pipes is coupled to the avionics unit, and defines a hot interface, and a second end of the first plurality of heat pipes is coupled to a portion of an aircraft that is exposed to an external environment outside the aircraft.

In another aspect, the disclosure relates to a method of thermal management. The method includes transferring heat from at least heat generating component to a first set of heat pipes located within in avionics unit, transferring heat from the first set of heat pipes, within the avionics unit, to a cold plate located on an exterior of the avionics unit, and transferring heat from a first end of a second set of heat pipes to a second end of the second set of heat pipes at least one of a fuselage, a wing, a skin, or a support structure of the aircraft.

Aspects of the present disclosure describe a thermal management system configured to provide cooling for heat generating components within an electronics chassis housing of an aircraft. For the purposes of illustration, the thermal management system of the present disclosure will be described with respect to identify multiple ways to not only cool a high powered computing unit within an aircraft, such as an electronics chassis, but to do so in a way that places less of a heat load on the Environmental Control System (ECS). It will be understood that the present disclosure is not so limited and can also have general applicability in non-aircraft environments, such as ground-based electrical systems or solar power distribution systems, and may also be used to provide benefits in industrial, commercial, and residential applications.

While aspects of the disclosure can have general applicability, a thermal management system will be described in an exemplary application of an avionics chassis. For example, aircraft and avionics can have high power demands or high-power density, and more efficient electrical and thermal management can be desirable for such applications. In such an environment, the thermal management system as described herein can use fundamental technologies such as passive cooling techniques that significantly reduce heat and reject the waste heat to the exterior of the aircraft, which can reduce costs for implementing cooling solutions.

All directional references (e.g., radial, axial, proximal, distal, upper, lower, upward, downward, left, right, lateral, front, back, top, bottom, above, below, vertical, horizontal, clockwise, counterclockwise, upstream, downstream, forward, aft, etc.) are used only for identification purposes to aid the reader's understanding of the present disclosure, and should not be construed as limiting on an embodiment, particularly as to the position, orientation, or use of aspects of the disclosure described herein. Connection references (e.g., attached, coupled, fixed, connected, joined, and the like) are to be construed broadly and can include intermediate members between a collection of elements and relative movement between elements unless otherwise indicated. As such, connection references do not necessarily infer that two elements are directly connected and in fixed relation to one another. Furthermore, as used herein, the term "set" or a "set" of elements can be any number of elements, including only one.

The exemplary drawings are for purposes of illustration only and the dimensions, positions, order and relative sizes reflected in the drawings attached hereto can vary. Additionally, as used herein, elements being "electrically connected," "electrically coupled," or "in signal communication" can include an electric transmission or signal being sent, received, or communicated to or from such connected or coupled elements. Furthermore, such electrical connections or couplings can include a wired or wireless connection, or a combination thereof.

Also, as used herein, the term "satisfies" regarding a threshold value is used to mean that the respective value or values satisfy the predetermined threshold, such as being equal to or less than the threshold value, or being within the threshold value range. For example, if a sensed value falls below a threshold value, the sensed value can "satisfy" the threshold. Additionally, as used herein, the term "exceeds" regarding a threshold value is used to mean that the respective value does not satisfy the predetermined threshold, such as being outside of a threshold value range, falling above a maximum threshold, or falling below a minimum threshold. For example, if a sensed value falls below a minimum threshold, the value can "exceed" the threshold. It will be understood that such a determination may easily be altered to be satisfied by a positive/negative comparison, exceeding comparison, or a true/false comparison.

<FIG> schematically depicts an aircraft <NUM> that can include one or more propulsion engines <NUM> coupled to a fuselage <NUM>, a cockpit <NUM> positioned in the fuselage <NUM>, and wing assemblies <NUM> extending outward from the fuselage <NUM>. While illustrated in a commercial airliner, aspects of the disclosure can be utilized in any type of aircraft, for example, without limitation, fixed-wing, rotating-wing, rocket, commercial aircraft, or personal aircraft. Furthermore, aspects of the disclosure are not limited only to aircraft aspects, and can be included in other mobile and stationary configurations. Non-limiting examples of such mobile configurations can include ground-based, water-based, or additional air-based vehicles.

The aircraft <NUM> can include an on-board chassis or avionics unit <NUM> (shown in phantom) for housing heat generating components. In a non-limiting example, the avionics unit <NUM> can be in the form of an electronics chassis for housing heat generating avionics or avionics components for use in the operation of the aircraft <NUM>. The avionics unit <NUM> can include thermal management members including, but not limited to, heat spreaders, heatsinks, heat exchanger, or radiators. The avionics unit <NUM> can be configured to house a variety of electronic components or avionics elements and protect them against contaminants, electromagnetic interference (EMI), radio frequency interference (RFI), vibrations, and the like, or combinations thereof.

While illustrated proximate to the cockpit <NUM>, it will be understood that the avionics unit <NUM> can be located anywhere within the aircraft <NUM>. For example, the avionics unit <NUM> can be located in the cockpit <NUM>, in a cabin of the aircraft <NUM>, or in a storage bay within the aircraft <NUM>, in further non-limiting examples.

According to aspects of the present disclosure a plurality of heat pipes <NUM> (shown in phantom), which can be fixed or modular are operably coupled to the avionics unit <NUM>. A heat pipe is a heat-transfer device that combines the principles of both thermal conductivity and phase transition to effectively transfer heat between two interfaces, generally a hot interface and a cold interface. At the hot interface of a heat pipe a liquid within the heat pipe in contact with a thermally conductive solid surface turns into a vapor by absorbing heat from that surface. The vapor then travels along the heat pipe to the cold interface and condenses back into a liquid, releasing the latent heat. The liquid then returns to the hot interface through either capillary action, centrifugal force, or gravity, and the cycle repeats. Due to the very high heat transfer coefficients for boiling and condensation, heat pipes are highly effective thermal conductors.

<FIG> illustrates the plurality of heat pipes <NUM> located near the nose of the aircraft <NUM> in the lower hemisphere. It is contemplated that this may provide the most beneficial location as the nose underneath the aircraft may receive cold airflow during flight and be shielded from sun while not in flight. However, it will be understood that the plurality of heat pipes <NUM> can be located in any location within the aircraft <NUM> including that the hot end and cold end can be placed in any suitable locations. In the illustrated example, the plurality of heat pipes <NUM> can have a first end 21a coupled to the avionics unit <NUM> and a second end 21b coupled to the fuselage <NUM> or a skin of the aircraft. In other non-limiting examples, the second end 21b of the plurality of heat pipes <NUM> can be coupled to the wing <NUM>, another support structure within the aircraft, or an exterior portion of the aircraft <NUM>. In addition, the second end 21b can be exposed to ambient air outside the aircraft <NUM>.

<FIG> illustrates the avionics unit <NUM> in the form of a chassis. In further detail, the avionics unit <NUM> can include a housing <NUM> defining an interior <NUM> and exterior <NUM>. The avionics unit <NUM> can include a frame <NUM> having a top cover <NUM>, a bottom wall <NUM>, a back wall <NUM>, and opposing sidewalls <NUM>, <NUM>. The frame <NUM> can further include a removable front cover <NUM>, providing access to the interior <NUM> of the avionics unit <NUM> when removed, and at least partially restricting access to the interior <NUM> when coupled or mounted to the frame <NUM>. In addition, the sidewalls <NUM>, <NUM> can include an interior surface <NUM> and an exterior surface <NUM>. The frame can be formed from any suitable material, such as aluminum or steel in non-limiting examples.

Optionally, a set of mounting feet <NUM> can extend from the housing <NUM> to facilitate mounting the avionics unit <NUM> to the aircraft <NUM> by means of bolts or other suitable fasteners. The set of mounting feet <NUM> can also function to electrically ground the avionics unit <NUM> to the frame of the aircraft <NUM>. While the example of <FIG> illustrates the set of mounting feet <NUM>, any desired type of attachment mechanism can be utilized to secure or ground the avionics unit <NUM> within the aircraft <NUM>. The avionics unit <NUM> can further include a set of card rails <NUM> within the interior <NUM> and supported by the interior surface <NUM> of the sidewalls <NUM>, <NUM>. The set of card rails <NUM> can be horizontally aligned on the interior surfaces <NUM> and spaced on opposing sidewalls <NUM>, <NUM> to define effective card slots <NUM> (illustrated by the phantom lines). An avionics system <NUM> including at least one avionics system card <NUM> can be housed within the avionics unit <NUM> by way of the card slots <NUM>, wherein each card slot <NUM> can be configured to receive at least a portion of an avionics system card <NUM>. While only one avionics system card <NUM> is shown, the avionics unit <NUM> can be configured to house, support, or include any number of avionics system cards <NUM>.

Each avionics system card <NUM> can include a set of wires (not shown). The set of wires can be formed of any suitable material, including copper or aluminum. At least one heat generating electronic component <NUM> can also be provided on the avionics system card <NUM>. It should be understood that the set of wires can be used within the electronic component <NUM> or to connect multiple electronic components <NUM>, or anywhere else within or on the avionics system card <NUM> as desired.

Heat generating components <NUM> in avionics can produce high heat loads, and traditional devices for heat dissipation can introduce an appreciable amount of extra weight to the aircraft. It can be beneficial to transfer heat both within the avionics unit and transfer heat from the avionics unit to structural portions of the aircraft that can dissipate the heat load to, by way of non-limiting example, ambient air exterior of the aircraft.

Aspects of the present disclosure include a thermal management system <NUM>. The thermal management system <NUM> includes the heat management exterior <NUM> of the avionics unit <NUM> and the interior <NUM> of the avionics unit <NUM>. Exterior <NUM> of the avionics unit <NUM> can include a cold plate <NUM>, which can form a first interface or a hot interface. More specifically the cold plate <NUM> is mounted to the avionics unit <NUM> and thermally coupled thereto. In this manner the cold plate <NUM> is thermally coupled to the heat generating component located therein. The cold plate <NUM> is thermally coupled to a heat spreader <NUM> located on the interior <NUM> of the avionics unit <NUM>. The plurality of heat pipes <NUM> (<FIG>) are also thermally coupled to such cold plate <NUM>. first end 21a of the plurality of heat pipes <NUM> is thermally coupled to the cold plate <NUM>. In the illustrated example the first end 21a is illustrated as being embedded into the cold plate <NUM>. The second end 21b of the plurality of heat pipes <NUM> is coupled to a structure of the aircraft.

A plurality of heat-dissipating fins <NUM> can extend from the exterior surface of the cold plate <NUM>. While other configurations are possible, the heat-dissipating fins <NUM> are illustrated having the same orientation as plurality of heat pipes <NUM> located therein and commensurate with the length of the cold plate <NUM>. The heat-dissipating fins <NUM> could be in alternative configurations including being only part of the length, having sets along the length, or running perpendicular to the plurality of heat pipes <NUM>. The heat-dissipating fins <NUM> increase the exterior surface area of the cold plate <NUM> and allow some heat to be transferred to the surrounding air through convection.

A heatsink <NUM> may be mounted directly to the PCB or heat generating component <NUM> or through a thermal pad. The heatsink <NUM> and any thermal pad may be made of any thermally conductivity material. The heatsink <NUM> or any thermal pad may be located such that it directly contacts the heat generating component <NUM>. While the heatsink <NUM> has been illustrated as a plane it will be understood that it may also be a bar, strap, or other configuration.

The heatsink <NUM> can include a second plurality of heat pipes or a set of embedded heat pipes <NUM>. The set of embedded heat pipes <NUM> can be formed of any suitable material, including copper or aluminum. The set of embedded heat pipes <NUM> can have a hot end 52a coupled to or embedded within the heatsink <NUM> and a cold end 52b coupled to or embedded in a heat spreader <NUM> that is located within the avionics unit <NUM>. The heat spreader <NUM> can be thermally coupled to the avionics unit <NUM> and mounted thereto. <FIG> illustrates the heat spreader <NUM> thermally coupled to the interior <NUM> of the top cover <NUM> of the housing <NUM>. It should be appreciated that the heat spreader <NUM> can be organized in multiple configurations.

During operation, heat is generated by the one or more heat generating components <NUM> and managed by the thermal management system <NUM>. A thermal path in the thermal management system <NUM> begins with the heat generating component <NUM>. Heat is conducted from the heat generating component <NUM> through the heatsink <NUM> to the second set of heat pipes <NUM>, which in turn transfers the heat to the heat spreader <NUM>. The heat is conductively transferred from the heat spreader <NUM> to the cold plate <NUM> via avionics unit <NUM>. Heat may be conducted to the heat-dissipating fins <NUM> where heat may then be dissipated through convection into the air surrounding the heat-dissipating fins <NUM>. The amount of heat dissipated via the heat-dissipating fins <NUM> is minimal compared to the transfer of heat from the cold plate <NUM> to the first set of heat pipes <NUM>. Heat is transferred from the hot end or first end 21a of the first set of heat pipes <NUM>, which can be coupled to or embedded in the cold plate <NUM>, to the cold end or second end 21b of the heat pipes <NUM>, which are thermally coupled to an aircraft structure. The aircraft structure can be located such that the heat is then rejected to ambient air located on the exterior of the aircraft <NUM>.

<FIG> flowchart illustrates a method <NUM> of operation of the thermal management system <NUM> in accordance with the operation described above. The method <NUM> can include transferring heat, at <NUM>, via the at least one heat generating component <NUM> through the heatsink <NUM> to the second set of heat pipes <NUM> located within the avionics unit <NUM>. At <NUM>, heat can be transferred from the second set of heat pipes <NUM> to the heat spreader <NUM>. Furthermore, at <NUM>, heat can be transferred to the exterior of the avionics unit <NUM>. For example, this can include transferring heat to a first interface formed by the cold plate <NUM>. This can be accomplished as the heat spreader <NUM> is thermally coupled to the cold plate <NUM>, which are both thermally coupled to the housing <NUM> of the avionics unit <NUM>. Optionally, heat may be conduct to the heat-dissipating fins <NUM> then dissipate to the air surrounding the avionics unit <NUM>. At the first interface, heat is transferred from the cold plate <NUM> to the first set of heat pipes <NUM>. At <NUM>, heat can also be transferred from the first set of heat pipes <NUM> to a portion of the aircraft's structure, such as the wing <NUM>, the fuselage <NUM>, the skin of the aircraft. In turn, heat can be rejected from this portion of the aircraft structure to ambient air located on the exterior of the aircraft.

<FIG> schematically illustrates the direction of heat flow, indicated overall with arrow <NUM>, beginning at the heat source <NUM> formed by the one or more heat generating components. It will be understood that the heat source <NUM> in this schematic illustration encompasses the entire avionics unit <NUM>. Heat can be transferred to the cold plate <NUM>, which is thermally coupled thereto. The cold plate <NUM> forms the first interface <NUM>, which can also be referred to as the hot interface. Heat is transferred from the first interface <NUM> through a plurality of heat pipes <NUM>. A second interface <NUM>, or cold interface, thermally couples the cold end of the heat pipes <NUM> to the aircraft structure <NUM>. Heat can then transfer from the aircraft structure <NUM> to ambient air located outside of the aircraft <NUM>.

Some advantages associated with the disclosure discussed herein can include, but are not limited to, reducing cost for implementing cooling solutions within an aircraft, give an alternative to thermal management with technologies that have space constraints, as well as give an alternative to applications where no cooling is currently provided. Aircraft have traditionally used the mass of fuel or air internal to the aircraft structure as a sink to which waste heat can be rejected. For example, ECS systems can utilize forced convection with liquid or air cooling, driven by fans and pumps that draw their power from the aircraft engines through engine bleed-air or electrical generators. Aspects of the present disclosure are passive and do not require such fans, pumps, power input, etc. Another advantage associated with the disclosure discussed herein can include eliminating the need for moving mechanical parts used for cooling purposes such as fans, or duct air components.

Additionally, heat pipes are highly reliable and suitable for long service life, which can also benefit thermal systems. Heat pipes are also able to exhibit extremely high apparent thermal conductivity because of their two-phase system, which can also be transferred over relatively long distances, while maintaining low weight due to their hollow tubing. An advantage of being coupled to a structure that is on an exterior of the aircraft is that ambient air temperature of the standard atmosphere approaches -<NUM> degrees Celsius at typical commercial aircraft cursing altitudes creating optimal temperature for heat to be extracted from the heat pipes through convection. Another advantage associated with the disclosure is that using heat pipes allows for omitting any components requiring electrical power, which can in turn reduce power needs for the aircraft, simplify mechanical designs of avionics, and reduce complexity of an entire cooling system. Another advantage of the system is that the system increases the flexibility that the airframer has in placing units on the aircraft.

Many other possible configurations in addition to those shown in the above figures are contemplated by the present disclosure. To the extent not already described, the different features and structures of the various aspects can be used in combination with others as desired. That one feature cannot be illustrated in all of the aspects is not meant to be construed that it cannot be, but is done for brevity of description. Thus, the various features of the different aspects can be mixed and matched as desired to form new aspects, whether or not the new aspects are expressly described. Combinations or permutations of features described herein are covered by this disclosure.

Claim 1:
A thermal management system (<NUM>), comprising:
an avionics unit (<NUM>) defining an interior (<NUM>) configured to house at least one heat generating component (<NUM>), wherein the avionics unit (<NUM>) comprises an electronics chassis (<NUM>) having an exterior (<NUM>) and defining the interior (<NUM>) for housing the at least one heat generating component (<NUM>);
a first plurality of heat pipes (<NUM>), wherein a first end (21a) of the first plurality of heat pipes (<NUM>) is coupled to the avionics unit (<NUM>), and defines a hot interface, and a second end (21b) of the first plurality of heat pipes (<NUM>) is coupled to a structural portion of an aircraft (<NUM>) that is thermally coupled to an external environment outside the aircraft (<NUM>);
wherein the hot interface further comprises a cold plate (<NUM>) operably coupled to the electronics chassis (<NUM>) and thermally coupled to the at least one heat generating component (<NUM>); and
a heat spreader (<NUM>), having a body located within the interior (<NUM>), thermally coupled to the electronics chassis (<NUM>) of the avionics unit (<NUM>);
wherein the heat spreader (<NUM>) further comprises a second plurality heat pipes (<NUM>) embedded in the heat spreader (<NUM>), the second plurality heat pipes comprising a hot end (52a) thermally coupled to the heat generating component (<NUM>) via a heatsink (<NUM>).