Method of manufacturing a heat transfer system for aircraft structures

Patent metadata

Field	Value
Publication number	US-9067287-B2
Application number	US-201113220343-A
Country	US
Kind code	B2
Filing date	Aug 29, 2011
Priority date	Aug 29, 2011
Publication date	Jun 30, 2015
Grant date	Jun 30, 2015

Abstract

A method of manufacturing a heat transfer system is provided that includes, in one form, preparing a heat conducting array by perforating at least a portion of the heat conducting array, placing the heat conducting array around foam elements, placing a heat conducting spreader along one surface area of the foam elements, placing a lower skin over the heat conducting spreader, placing an upper skin over an opposite surface area of the foam elements to create a structural assembly, and curing the structural assembly. A material of the foam elements flows through the perforated portion of the heat conducting array during the curing step.

First claim

The invention claimed is:

1. A method of manufacturing a heat transfer system comprising:
preparing a heat conducting array by perforating at least a portion of the heat conducting array;
placing the heat conducting array around foam elements;
placing a heat conducting spreader along one surface area of the foam elements;
placing a lower skin over the heat conducting spreader;
placing an upper skin over an opposite surface area of the foam elements to create a structural assembly; and
curing the structural assembly by a vacuum autoclave,
wherein a material of the foam elements flows through the perforated portion of the heat conducting array during the curing step.

2. The method according to claim 1 , wherein the heat conducting array is a pyrolytic graphite sheet (PGS) material.

3. The method according to claim 1 , wherein the heat conducting spreader is a pyrolytic graphite sheet (PGS) material.

4. The method according to claim 1 , wherein the heat conducting array defines at least one upper cap, at least one lower cap, and a wall portion extending between at least one upper cap and at least one lower cap when placed around the foam elements, and the wall portion is perforated.

5. The method according to claim 1 further comprising applying a moisture-proof layer over the upper skin.

6. The method according to claim 5 , wherein the moisture-proof layer is an ethylene-co-methacrylic acid (EMAA) material.

7. A method of manufacturing a heat transfer system comprising:
preparing a heat conducting array by perforating at least a portion of the heat conducting array, the heat conducting array comprising a pyrolytic graphite sheet (PGS) material;
placing the heat conducting array around foam elements;
placing a heat conducting spreader along one surface area of the foam elements, the heat conducting spreader comprising a pyrolytic graphite sheet (PGS) material;
placing a lower skin over the heat conducting spreader;
placing an upper skin over an opposite surface area of the foam elements to create a structural assembly; and
curing the structural assembly by a vacuum autoclave,
wherein a material of the foam elements flows through the perforated portion of the heat conducting array during the curing step.

8. The method according to claim 7 , wherein the heat conducting array defines at least one upper cap, at least one lower cap, and a wall portion extending between at least one upper cap and at least one lower cap when placed around the foam elements, and the wall portion is perforated.

9. The method according to claim 7 further comprising applying a moisture-proof layer over the upper skin.

10. The method according to claim 9 , wherein the moisture-proof layer is an ethylene-co-methacrylic acid (EMAA) material.

11. A method of manufacturing a heat transfer system comprising:
preparing a heat conducting array by perforating at least a portion of the heat conducting array;
placing the heat conducting array around foam elements;
placing a lower skin over one surface area of the foam elements;
placing an upper skin over an opposite surface area of the foam elements to create a structural assembly; and
forming the structural assembly under heat and pressure,
wherein a material of the foam elements extends through the perforated portion of the heat conducting array during the forming step.

12. The method according to claim 11 , wherein the heat conducting array is a pyrolytic graphite sheet (PGS) material.

13. The method according to claim 11 further comprising placing a heat conducting spreader between the lower skin and the core elements.

14. The method according to claim 13 , wherein the heat conducting spreader is a pyrolytic graphite sheet (PGS) material.

15. The method according to claim 11 , wherein the heat conducting array defines at least one upper cap, at least one lower cap, and a wall portion extending between at least one upper cap and at least one lower cap when placed around the core elements, and the wall portion is perforated.

16. The method according to claim 11 , wherein the structural assembly is cured in a vacuum autoclave.

17. The method according to claim 11 , wherein the structural assembly is formed in a press.

Assignees

• Ofoma Uchenna
• Hibbs Bart Dean
• Olch Ronald
• Mcallister Justin B
• Aerovironment Inc

Inventors

• Ofoma Uchenna
• Hibbs Bart Dean
• Olch Ronald
• Mcallister Justin B

Classifications

• H10W40/43

  by flowing gases, e.g. forced air cooling · CPC title

• H10W40/00

  Arrangements for thermal protection or thermal control (integrated devices comprising arrangements for thermal protection H10D89/60) · CPC title

• B23P15/26 Primary

  heat exchangers {or the like (making heat exchangers by methods covered by other subclasses B21D53/02)} · CPC title

• B32B37/142

  Laminating of sheets, panels or inserts, e.g. stiffeners, by wrapping in at least one outer layer, or inserting into a preformed pocket · CPC title

• Y10T29/4935

  Heat exchanger or boiler making · CPC title