Patent Description:
A water collector or water extractor may be provided within an environmental control system to capture or remove free moisture from an airflow. The water collector may include a separation device that directs the moisture present within the airflow to outer walls of the separation device and direct the free moisture towards a drain port. Often times the water collector may be substantially bulky and consume large amounts of space.

According to an embodiment, a water extractor for use in an environmental control system includes a housing having an inlet end and an outlet end. A fog harvester assembly is mounted within the housing at a location between the inlet end and the outlet end. The fog harvester assembly includes at least one fog harvester insert having a condensing material including plurality of wires arranged in a wire array. At least one of the plurality of wires has a spiral configuration.

In addition to one or more of the features described above, or as an alternative, in further embodiments the housing includes a diffuser, the fog harvester assembly being arranged at a downstream end of the diffuser.

In addition to one or more of the features described above, or as an alternative, in further embodiments the fog harvester assembly includes a plurality of fog harvester inserts.

In addition to one or more of the features described above, or as an alternative, in further embodiments the plurality of fog harvester inserts are separated from one another along an axis of the housing such that a medium is configured to pass through the plurality of fog harvester inserts in series.

In addition to one or more of the features described above, or as an alternative, in further embodiments comprising at least one spacer arranged between adjacent fog harvester inserts of the plurality of fog harvester inserts.

In addition to one or more of the features described above, or as an alternative, in further embodiments the plurality of wires of the wire array are arranged in at least two rows.

In addition to one or more of the features described above, or as an alternative, in further embodiments the spiral configuration of adjacent wires is varied.

In addition to one or more of the features described above, or as an alternative, in further embodiments the condensing material of the at least one fog harvester insert is mounted to a frame. The plurality of wires have a vertical orientation relative to the frame.

The condensing material of the at least one fog harvester insert is mounted to a frame. A bottom of the frame has one or more holes formed therein.

An end plate is positioned in overlapping arrangement with the at least one fog harvester insert. The end plate has a bottom lip and a height of the bottom lip is extended relative to a height of the bottom of the frame.

In addition to one or more of the features described above, or as an alternative, in further embodiments the end plate further comprises a plurality of fasteners for attaching the fog harvester assembly to the housing.

In addition to one or more of the features described above, or as an alternative, in further embodiments comprising a seal positioned between the end plate and the at least one fog harvester insert.

In addition to one or more of the features described above, or as an alternative, in further embodiments the housing further comprises an internal flange and movement of the fog harvester assembly being restricted in a first direction by the internal flange.

According to an embodiment, an environmental control system of a vehicle includes a component and a water extractor arranged downstream from and in fluid communication with the component relative to a flow of medium. The water extractor includes a housing having an inlet end and an outlet end and a fog harvester assembly mounted within the housing at a location between the inlet end and the outlet end. The fog harvester assembly includes at least one fog harvester insert having a condensing material including plurality of wires arranged in a wire array and at least one of the plurality of wires has a spiral configuration.

In addition to one or more of the features described above, or as an alternative, in further embodiments the vehicle is an aircraft.

In addition to one or more of the features described above, or as an alternative, in further embodiments the component is a turbine.

In addition to one or more of the features described above, or as an alternative, in further embodiments the housing includes a diffuser and the fog harvester assembly is arranged at a downstream end of the diffuser.

In addition to one or more of the features described above, or as an alternative, in further embodiments comprising a swirling mechanism mounted within the housing, upstream from the diffuser.

In addition to one or more of the features described above, or as an alternative, in further embodiments the fog harvester assembly includes a plurality of fog harvester inserts arranged in series relative to the flow of medium.

With reference now to the <FIG>, an exemplary portion of an environmental control system <NUM> is illustrated. As shown, the environmental control system (ECS) <NUM> includes an air cycle machine <NUM> having a turbine <NUM>, and in some embodiments includes one or more other components, such as a compressor <NUM> and a fan <NUM> operably coupled to the turbine <NUM> by a rotatable shaft <NUM> for example. In the illustrated, non-limiting embodiment, the water extractor <NUM> is arranged downstream from the outlet of the turbine <NUM>. However, it should be understood that embodiments where the water extractor <NUM> is arranged downstream from any suitable component of the ECS <NUM> are also contemplated herein. In an embodiment, the water extractor <NUM> is positioned within the ECS <NUM> to receive a flow of medium or air A that is cool and has condensed water vapor entrained or suspended therein resulting in a fog-like consistency.

With reference now to <FIG>-<NUM>, a non-limiting embodiment of a water extractor <NUM> is shown in more detail. The water extractor <NUM> includes a housing <NUM> having an inlet end <NUM> and an outlet end <NUM>. As previously noted, the inlet end <NUM> may be configured to couple directly or indirectly to an outlet of a turbine. Similarly, the outlet end <NUM> may be configured to couple the housing <NUM> with a downstream component (not shown) of the ECS <NUM>, such as a heat exchanger or a converging outlet header for example. In an embodiment, the outlet end <NUM> includes an outwardly extending flange <NUM> configured to facilitate a connection with the downstream component.

In the illustrated, non-limiting embodiment, the cross-sectional area of the housing <NUM> adjacent to or near the inlet end <NUM> is substantially smaller than the cross-sectional area of the housing at or adjacent to the outlet end <NUM>. This change in the cross-sectional area is selected to cause a change in one or both of the pressure of the medium A and the speed of the medium A as is flows through the housing <NUM>. Accordingly the configuration of the housing <NUM> may be selected in part to achieve a flow at the outlet end <NUM> or upstream from the outlet end <NUM> having a desirable speed associated with one or more downstream components of the ECS <NUM>. However, embodiments where the cross-sectional area at the outlet end <NUM> is substantially equal to or only slightly larger than the cross-sectional area at the inlet end <NUM> are also within the scope of the disclosure.

As shown, the housing <NUM> may have a first portion <NUM> extending from the inlet end <NUM>, and a second portion <NUM> extending from the outlet end <NUM>, and a third portion <NUM> disposed between the first portion <NUM> and the second portion <NUM>. In an embodiment, the first portion <NUM> of the housing <NUM> has a substantially constant cross-sectional shape and area. In the illustrated, non-limiting embodiment, the first portion <NUM> of the housing <NUM> is generally cylindrical; however, a first portion <NUM> having any suitable configuration is contemplated herein. Although not shown, a swirling mechanism may be arranged within the first portion <NUM> of the housing <NUM>, such as at a location near the inlet end <NUM> for example. Such a swirling mechanism may be configured to impart a swirl or spin on the medium thereby enhancing the distribution of the medium A, and in particular the water within the medium A, across the entire area of the housing <NUM>.

The cross-sectional area and/or the cross-sectional shape of the third portion <NUM> of the housing <NUM> may vary over the axial length thereof. As a result of the change in the cross-sectional area of the third portion <NUM> along the axis, the third portion <NUM> may form a diffuser reducing the velocity and increasing the static pressure of the medium A. In an embodiment, the third portion <NUM> of the housing <NUM> has a generally circular cross-section such that the third portion <NUM> is substantially frustoconical in shape.

The second portion <NUM> of the housing <NUM> may have a generally constant cross-sectional shape and area. Although the second portion <NUM> of the housing <NUM> is illustrated as being generally cylindrical in shape it should be understood that a second portion <NUM> having another suitable configuration is contemplated herein. As best shown in <FIG>, in an embodiment, one or more sides of the circular wall that forms the second portion <NUM> may include one or more straight or linear sections <NUM>. Although these straight sections are illustrated as being arranged at opposite lateral sides of the housing <NUM>, embodiments where the at least one straight section is arranged elsewhere about the periphery of the second portion <NUM> are also contemplated herein.

Mounted within the housing <NUM>, such as within the second portion <NUM> near the outlet end <NUM> (see <FIG> and <FIG>), is a fog harvester assembly <NUM> including at least one fog harvester insert <NUM>. In the illustrated, non-limiting embodiment of <FIG>, the fog harvester assembly <NUM> includes two fog harvester inserts <NUM>. However, it should be understood that a fog harvester assembly <NUM> having any number of fog harvester inserts <NUM>, including a single fog harvester insert, three fog harvester inserts, or more than three fog harvester inserts for example, are within the scope of the disclosure. In embodiments including multiple fog harvester inserts <NUM>, the plurality of fog harvester inserts <NUM> are stacked relative to one another along the axis of the housing <NUM>, such that the medium is configured to flow through the plurality of fog harvester inserts <NUM> in series. Further, in embodiments including multiple fog harvester inserts <NUM>, the configuration of each of the plurality of fog harvester inserts <NUM> may be substantially identical, or alternatively, may be different.

Each fog harvester insert <NUM> includes a frame <NUM> and a condensing material <NUM> installed about the frame <NUM>. The frame <NUM> may be formed in any suitable manner including, but not limited to cast, injection molded, additively formed, and machined for example. The frame <NUM> is generally complementary to the corresponding portion of the housing <NUM> within which the fog harvester assembly <NUM> is received. In the illustrated, non-limiting embodiment, the frame <NUM> defines a periphery of the fog harvester insert <NUM> and is generally circular in shape. In embodiments where the second portion <NUM> of the housing <NUM> includes at least one straight section <NUM>, the frame <NUM> may similarly include a straight section <NUM> positionable in alignment with the straight section <NUM> of the second portion <NUM> of the housing <NUM>. Although the frame <NUM> is illustrated as only being arranged at a periphery of the fog harvester insert <NUM>, embodiments where the frame <NUM> additionally includes at least one centrally located support extending between the sides of the frame <NUM> are also contemplated herein.

With continued reference to <FIG>, one or more holes or elongated slots <NUM> are formed at or adjacent to the bottom surface <NUM> of the frame <NUM> to fluidly couple the bottom of the frame <NUM> with a sump or drain <NUM> formed in an adjacent surface of the housing <NUM>. In the illustrated, non-limiting embodiment, the at least one hole <NUM> includes a single slot extending about at least <NUM> degrees of the periphery, such as <NUM> degrees or more, or even <NUM> degrees or more. Although the slot <NUM> is shown as extending over only a portion of the width of the frame <NUM> (the slot is shown formed at a center of the frame <NUM>), embodiments where the one or more holes <NUM> extend over a substantial entirety of the width of the frame <NUM> are also within the scope of the disclosure.

With continued reference to <FIG>-<NUM>, in the illustrated, non-limiting embodiment, the condensing material <NUM> includes a plurality of wires <NUM> arranged within an array, each wire has helical or spiral configuration. The wires <NUM> may be mounted relative to the frame <NUM> in a vertical orientation such that the wires <NUM> are parallel to one another and a first end of each wire <NUM> is coupled to a first end or top <NUM> of the frame <NUM> and a second end of each wire <NUM> is coupled to a second, opposite end or bottom <NUM> of the frame <NUM>. However, embodiments where the wires <NUM> have another orientation are also contemplated herein.

The plurality of wires <NUM> within the array may be made of any suitable material. Examples of suitable materials include, but are not limited to steel, steel alloys, copper, aluminum, other metals or metal alloys, composites, nylon, polyester, rayon, or another suitable polymer or plastic material, or any combination thereof. As shown, the wire array associated with each fog harvester insert <NUM> includes a plurality of rows of wires or strings <NUM> arranged in series relative to the flow through the housing <NUM>. Although two rows of wires <NUM> are shown (<FIG>), it should be understood that a fog harvester insert <NUM> having any number of rows of strings, including three rows, four rows, five rows, or more than five rows for example, are contemplated herein.

Each row within the array includes one or more wires. As best shown in <FIG>, the wires within each row may be positioned such that an outer periphery of the circular shape formed by the spiral of a first wire (in plan view) is directly adjacent to the circular shape formed by the spiral of a second wire (in plan view). Accordingly, the center of each spiral wire <NUM> is offset from the center of an adjacent spiral wire by a distance equal to an outer diameter of the circular shape of the spiral wires <NUM>. Further, the spirals of adjacent wires within a row are not configured to overlap or intertwine with one another. Alternatively, or in addition, the spiral wires within adjacent rows, such as the first wires of the plurality of rows for example, may also be arranged so as not to overlap or intertwine. However, it should be understood that embodiments where adjacent spiral wires <NUM> within a row, or alternatively or additionally, spiral wires <NUM> within adjacent rows intertwine are also within the scope of the disclosure.

In addition, as best shown in <FIG>, the direction of the spiral of the wires <NUM>, also referred to herein as the "spiral configuration", within a row is configured to vary. For example, a first wire has a left-hand or clockwise configuration and a second wire, for example positioned directly adjacent to the first wire, has a right-hand or counter clockwise configuration. Similarly, the first wire within adjacent rows may have alternating configurations.

In the illustrated, non-limiting embodiment of <FIG>, the plurality of fog harvester inserts <NUM> within the fog harvester assembly <NUM> are separated from one another by a distance. As shown, at least one spacer <NUM>, such as a frame for example, may be arranged between adjacent fog harvester inserts <NUM>. In the illustrated, non-limiting embodiment, the spacer <NUM> is substantially identical to the frame <NUM> of a fog harvester insert <NUM>. However, embodiments where a spacer <NUM> having a different configuration is used are also contemplated herein.

With continued reference to <FIG>, in an embodiment, the housing <NUM> is contoured or has an internal flange <NUM> (best shown in <FIG>) arranged near the outlet end <NUM>, for example near a downstream end of the third portion or diffuser <NUM> of the housing <NUM>, and configured to support an internal end of the fog harvester assembly <NUM>. The internal flange <NUM> restricts movement of the fog harvester assembly <NUM> in a first direction relative to the housing <NUM>. The fog harvester assembly <NUM> may be sealed against the flange <NUM> such as via an O-ring type seal (not shown) for example.

An end plate <NUM> is arranged in overlapping relationship with the most downstream fog harvester insert <NUM>, located adjacent to the outlet end <NUM> of the housing <NUM>. The end plate <NUM> has a substantially hollow center, similar to a frame <NUM> or spacer <NUM>, to reduce interference with the flow output from the housing <NUM>. In an embodiment, a seal <NUM>, such as an O-ring type seal for example, is positioned between the fog harvester assembly <NUM> and the end plate <NUM>.

A height (measured vertically) of a bottom lip <NUM> of the end plate <NUM> is greater than the vertical height of the bottom <NUM> of the frames <NUM> and/or spacers <NUM> of the fog harvester inserts <NUM>. As a result, the enlarged bottom lip <NUM> of the end plate <NUM> prevents any condensation collected near the bottom of the frame of the fog harvester inserts from becoming entrained in the airflow at the outlet end <NUM>.

When installed, the condensing material <NUM> of the one or more fog harvester inserts <NUM> of the fog harvester assembly <NUM> extend generally vertically such that any moisture that collects on the wires <NUM> of the condensing material <NUM> will slide along the wires <NUM> towards the one or more holes <NUM> at the bottom <NUM> of the frame <NUM> in response to the gravity acting thereon. Although the fog harvester inserts <NUM> are generally described herein such that the condensing material <NUM> has a vertical orientation, embodiments where the condensing material <NUM> is arranged at a non-vertical angle relative to the longitudinal axis of the housing <NUM> are also within the scope of the disclosure.

A plurality of fasteners, illustrated at <NUM>, may be used to couple the end plate <NUM> to a surface of the housing <NUM>. Although a plurality of clips that use a threaded connection are illustrated in the FIGS. , any suitable fastener is within the scope of the disclosure. When installed, movement of the fog harvester assembly <NUM> relative to the housing <NUM> is restricted by the internal flange <NUM> and the clips <NUM>.

In operation, the medium A is provided to the inlet end <NUM> of the water extractor <NUM>. As the medium A flows through the one or more fog harvester inserts <NUM> of the fog harvester assembly <NUM>, water droplets collect on the surface of the wires <NUM> of the condensing material <NUM>, or between adjacent layers of the condensing material <NUM>, such as between two or more wires <NUM> for example. As a result, the medium A output from the water extractor <NUM> is dried or dehumidified compared to the inlet air. When the droplets reach a sufficient size or volume, the gravitational force acting thereon will cause the droplets to slide down the condensing material <NUM> to the bottom of the frame <NUM>. At the bottom of the frame <NUM>, the water passes through the one or more holes <NUM> and drips from the end of the fog harvester insert <NUM> into the drain <NUM> disposed vertically underneath the fog harvester assembly <NUM>. From the drain <NUM>, the water can be exhausted overboard, or alternatively, can be redirected to another component of the ECS <NUM>, or alternatively, to another system or component of the aircraft.

Because the water extractor <NUM> illustrated and described herein is intended to coalesce and collect the moisture within the medium A, use of a water extractor <NUM> as described herein may minimize or even eliminate the need for a separate condenser located upstream from the water extractor <NUM> within the environmental control system.

Claim 1:
A water extractor (<NUM>) for use in an environmental control system, the water extractor comprising:
a housing (<NUM>) having an inlet end (<NUM>) and an outlet end (<NUM>); and
a fog harvester assembly (<NUM>) mounted within the housing (<NUM>) at a location between the inlet end (<NUM>) and the outlet end (<NUM>), the fog harvester assembly (<NUM>) including at least one fog harvester insert (<NUM>) having a condensing material (<NUM>) including plurality of wires (<NUM>) arranged in a wire array, wherein at least one of the plurality of wires (<NUM>) has a spiral configuration;
wherein the condensing material (<NUM>) of the at least one fog harvester insert is mounted to a frame (<NUM>), wherein a bottom of the frame (<NUM>) has one or more holes formed therein; and characterized by:
an end plate (<NUM>) positioned in overlapping arrangement with the at least one fog harvester insert (<NUM>), the end plate (<NUM>) having a bottom lip (<NUM>), wherein a height of the bottom lip is extended relative to a height of the bottom of the frame (<NUM>).