Abstract: A fan inlet diffuser housing system includes an air cycle machine, a housing coupled to the air cycle machine, an inlet fan disposed on the air cycle machine and configured to pass inlet air into the fan inlet diffuser housing, a center tube disposed in the housing, a diffuser cone disposed around the center tube, an inboard strut supporting the inner tube within the diffuser cone, and an outboard strut supporting the inner tube within the diffuser cone, the outboard strut being integral with the diffuser cone, wherein the inboard strut is coupled to the inner tube with a first plurality of mechanical fasteners, and the outboard strut is coupled to the inner tube with a second plurality of mechanical fasteners.

Abstract: An air cycle machine has a housing which holds a compressor section, and a turbine section having an expansion area, and a fan section disposed outside of the housing. A shaft, which attaches to and is coaxial with the compressor section, the turbine section and the fan section, is supported by an air journal bearing and an air thrust bearing. The shaft has a hollow core for porting cooling air from the air journal bearing and the air thrust bearing, and a tube that extends into said expansion area and communicates cooling air from the turbine expansion area to the thrust bearing.

Abstract: Disclosed is a bearing sleeve for supporting a shaft of an air cycle machine. The bearing sleeve includes an outer diameter and an inner diameter. The outer diameter is within a range of 3.222 and 3.224 inches. Further included is a foil retaining cavity provided in the inner diameter of the sleeve. The foil retaining cavity includes a slot and first and second openings located at opposing axial ends of the slot. Each of the first and second openings include a small portion and a large portion having different axial lengths. A ratio of the combined axial lengths of the large portions to an axial length of the foil retaining cavity is within a range of 0.19:1 and 0.22:1. Further included is a seal attachment portion provided at one axial end of the bearing sleeve configured to circumferentially support a seal.

Abstract: Disclosed is a bearing sleeve for supporting a shaft of an air cycle machine. The bearing sleeve includes an outer diameter and an inner diameter. The outer diameter is within a range of 3.214 and 3.216 inches. Further included is a foil retaining cavity provided in the inner diameter of the sleeve. The foil retaining cavity includes a slot and first and second openings located at opposing axial ends of the slot. Each of the first and second openings include a small portion and a large portion having different axial lengths. A ratio of the combined axial lengths of the large portions to an axial length of the foil retaining cavity is within a range of 0.19:1 and 0.22:1. Further included is a seal attachment portion provided at one axial end of the bearing sleeve configured to circumferentially support a seal.

Abstract: An air cycle machine has a housing which holds a compressor section, and a turbine section having an expansion area, and a fan section disposed outside of the housing. A shaft, which attaches to and is coaxial with the compressor section, the turbine section and the fan section, is supported by an air journal bearing and an air thrust bearing. The shaft has a hollow core for porting cooling air from the air journal bearing and the air thrust bearing, and a tube that extends into said expansion area and communicates cooling air from the turbine expansion area to the thrust bearing.

Abstract: A ram air fan inlet housing for containing a ram air fan rotor. The inlet housing includes a flanged surface and an interior surface. The flanged surface is perpendicular to an axis of the inlet housing and defines a flange plane at an axial end of the inlet housing. The interior surface is symmetric about the axis of the inlet housing and includes a flange section, a transition section, an outlet section, a rotor section, and an inlet section.

Abstract: A nozzle for an air cycle machine. The nozzle has a disk section having a central axis. The nozzle also includes a plurality of blades which extend a blade height H from a bladed face of the disk section. The plurality of blades are arranged radially about the disk section. The nozzle has a throat width W defined between each radially adjacent pair of the plurality of turbine blades. The nozzle includes a coating substantially encapsulating the disk section and the plurality of blades, wherein the coating contains more than 91 percent tungsten carbide by volume.

Abstract: A cabin air compressor drive ring includes an outer ring defining an axis, an inner ring co-axial with the outer ring, a plurality of webbings connecting the inner ring to the outer ring, and a plurality of vane engagement pins axially protruding from the outer ring. The vane engagement pins are spaced circumferentially about the outer ring, and the inner ring includes a drive ring bearing interface.

Abstract: Disclosed is a bearing sleeve for supporting a shaft of an air cycle machine. The bearing sleeve includes an outer diameter and an inner diameter. The outer diameter is within a range of 3.214 and 3.216 inches. Further included is a foil retaining cavity provided in the inner diameter of the sleeve. The foil retaining cavity includes a slot and first and second openings located at opposing axial ends of the slot. Each of the first and second openings include a small portion and a large portion having different axial lengths. A ratio of the combined axial lengths of the large portions to an axial length of the foil retaining cavity is within a range of 0.19:1 and 0.22:1. Further included is a seal attachment portion provided at one axial end of the bearing sleeve configured to circumferentially support a seal.

Abstract: Disclosed is a bearing sleeve for supporting a shaft of an air cycle machine. The bearing sleeve includes an outer diameter and an inner diameter. The outer diameter is within a range of 3.222 and 3.224 inches. Further included is a foil retaining cavity provided in the inner diameter of the sleeve. The foil retaining cavity includes a slot and first and second openings located at opposing axial ends of the slot. Each of the first and second openings include a small portion and a large portion having different axial lengths. A ratio of the combined axial lengths of the large portions to an axial length of the foil retaining cavity is within a range of 0.19:1 and 0.22:1. Further included is a seal attachment portion provided at one axial end of the bearing sleeve configured to circumferentially support a seal.

Abstract: Disclosed is a bearing sleeve for supporting a shaft of an air cycle machine. The bearing sleeve includes an outer diameter and an inner diameter. The outer diameter is within a range of 3.222 and 3.224 inches. Further included is a foil retaining cavity provided in the inner diameter of the sleeve. The foil retaining cavity includes a slot and first and second openings located at opposing axial ends of the slot. Each of the first and second openings include a small portion and a large portion having different axial lengths. A ratio of the combined axial lengths of the large portions to an axial length of the foil retaining cavity is within a range of 0.19:1 and 0.22:1.

Abstract: Disclosed is a bearing sleeve for supporting a shaft of an air cycle machine. The bearing sleeve includes an outer diameter and an inner diameter. The outer diameter is within a range of 3.214 and 3.216 inches. Further included is a foil retaining cavity provided in the inner diameter of the sleeve. The foil retaining cavity includes a slot and first and second openings located at opposing axial ends of the slot. Each of the first and second openings include a small portion and a large portion having different axial lengths. A ratio of the combined axial lengths of the large portions to an axial length of the foil retaining cavity is within a range of 0.19:1 and 0.22:1.

Abstract: A fan shield for an air cycle machine includes a fan shield body in the general shape of a frustum of a cone having curved sides. The curved sides define a radius of curvature and a center point of curvature that corresponds to the radius of curvature. The center point of curvature is an axial distance from a large end of the fan shield body and a radial distance from the central axis such that a ratio of the radial distance to the axial distance is between 1.160 and 1.360. A bearing housing includes a body that defines a cylindrical portion and an annular flange at one end. The annular flange includes a first attachment opening, a second attachment opening and a third attachment opening that are non-uniformly circumferentially spaced around the flange.

Abstract: An air cycle machine includes turbine and compressor housings respectively having a turbine and a compressor. An insulator seal plate is fastened between the turbine and compressor housings. The insulator seal plate includes a bore. A seal has an outer diameter that engages the bore. The seal also includes an inner diameter provided between lateral sides defining a first width. The inner diameter provides a seal and configured to engage a rotating surface. The outer diameter to the inner diameter provides a first ratio of 1.30-1.31. The inner diameter to the first width provides a second ratio of 1.59-1.61. A rotor shaft is disposed in the seal and includes knife edges extending from the rotor shaft to the seal land. The rotor shaft supports the turbine and the compressor.

Abstract: A terminal assembly has a terminal box including a divider extending in a front-to-rear direction of the terminal box and dividing the terminal box into a first chamber and a second chamber, the first chamber being larger than the second chamber and a terminal block mounted in the first chamber configured to have a plurality of contacts mounted onto the terminal block.

Abstract: An example housing of a cabin air compressor assembly includes a main body portion and a motor outlet duct extending radially from the main body portion. The motor outlet duct interfaces with the main body portion at an interface area. A ratio of a radius of the interface area to an inner diameter of the motor outlet duct is from 0.113 to 0.162.

Abstract: A cabin air compressor heat housing for a cabin air compressor assembly includes a compressor inlet extending from a body of the cabin air compressor heat housing. The cabin air compressor heat housing also includes an add-heat valve interface extending transversely from the compressor inlet. The cabin air compressor heat housing further includes a diffuser actuator interface formed in the body of the cabin air compressor heat housing. A ratio of a diameter of the compressor inlet to a diameter of the diffuser actuator interface is between 1.90 and 1.98.

Abstract: A cabin air compressor housing for a cabin air compressor assembly includes a compressor volute configured to direct a compressed flow to a compressor outlet. The cabin air compressor housing also includes a journal bearing support having a journal bearing bore. The cabin air compressor housing further includes an interior portion between the compressor volute and the journal bearing support. The interior portion includes a plurality of cooling airflow holes having a ratio of a diameter of the journal bearing bore to a diameter of one of the cooling airflow holes between 3.64 and 4.52.

Abstract: A turbine shroud for an air cycle machine includes a wall inner surface which at least partially defines a turbine flowpath, the wall inner surface defined by set of points in Table T-1 scaled by a desired factor.

Abstract: A compressor housing for an air cycle machine includes an inlet and an outlet. The compressor housing additionally includes a plurality of ribs that extend generally perpendicularly from a surface of the compressor housing. Formed within an internal region of the compressor housing is a bearing support structure. The bearing support structure receives and limits the axial movement of a bearing, seal and at least one O-ring.