Abstract: An air-liquid heat exchanger assembly for an environmental control system of an aircraft includes a heat exchanger, a controller, and a bypass valve. The heat exchanger includes a first chamber and a second chamber. The first chamber has a first inlet that is provided a liquid and a first end that is provided air. The second chamber is arranged adjacent the first chamber. The bypass valve is operably coupled to the controller. The bypass valve having an inlet coupled to a first outlet of the first chamber, a first outlet coupled to a second inlet of the second chamber, and a second outlet coupled to a bypass conduit. The controller adjusts a position of the bypass valve to control the flow of liquid through the second chamber and the bypass conduit.

Abstract: An environmental control system includes two environmental control system components with a duct extending between them. There is a drain in the duct including an orifice through the duct, a plenum in serial fluid communication with the orifice; and an orifice device removably connected to the duct, the orifice device including a second orifice in serial fluid communication with the plenum and the first orifice.

Abstract: A method of controlling an outlet temperature of a heat exchanger of an aircraft includes operating an air cycle machine at a first operating speed. The air cycle machine is operatively coupled to an air cycle machine bypass valve at a first position. The air cycle machine is fluidly connected to a first heat exchanger disposed adjacent to a second heat exchanger. In response to a second heat exchanger outlet temperature less than a second heat exchanger outlet temperature threshold while the aircraft is operating at an altitude less than an altitude threshold, the method moves the air cycle bypass valve from the first position toward a second position.

Abstract: A recirculation heat exchanger for use in an environmental control system of an aircraft is provided including a rectangular core having a plurality of alternately stacked first fluid layers and second fluid layers. The rectangular core has a width of about 4.750 inches (12.065 cm), and a length of about 10.6 inches (26.924 cm). A first air header is arranged adjacent a first surface of the core and a second air header is arranged adjacent a second, opposite surface of the core. The first and second air header form a portion of a flow path for a first fluid. A first fluid header is arranged adjacent a third surface and a second fluid header is arranged adjacent a fourth surface of the core. The first and second fluid header form a flow path for the second fluid having a multi-pass configuration.

Abstract: A heat exchanger includes a plurality of mini-channel tubes. The mini-channel tubes extends for an axial length defined between two manifolds. The mini-channel tubes include a plurality of generally rectangular flow passages. The generally rectangular flow passages are aligned adjacent to each other to define a lateral dimension. A first lateral width of the generally rectangular passages is defined with a ratio of the axial length to the first lateral width being between 201.3 and 215.3. An aircraft system is also disclosed.

Abstract: A channel tube includes a body having first and second surfaces extending between first and second opposing ends to define a tube width. The first and second surfaces are separated from each other by a distance defining a tube height. A plurality of ports extend through the body and between the first and second surfaces to define a fluid path extending in a direction of the tube width. Each port defines a plurality of walls and a plurality of ribs having a thermal conductive surface to transfer heat therethrough. A first wall extends in a direction of the tube width. The second wall extends in a direction of the tube width and is disposed opposite the first wall. At least one rib is integrally formed between the first and second walls and extends perpendicular thereto.

Abstract: A multi-chamber heat exchanger header includes a header housing and an insert. The header housing has a first wall and a second wall generally opposite the first wall where the first and second walls define a track. The insert is positioned to engage with the track such that the insert separates the header into first and second manifold chambers. A method for forming a multi-chamber heat exchanger header includes extruding a header housing having first and second manifold chambers and a track, positioning an insert in the header housing to engage with the track, and welding or brazing the insert to the header housing.

Abstract: A heat exchanger includes a plurality of mini-channel tubes. The mini-channel tubes extends for an axial length defined between two manifolds. The mini-channel tubes include a plurality of generally rectangular flow passages. The generally rectangular flow passages are aligned adjacent to each other to define a lateral dimension. A first lateral width of the generally rectangular passages is defined with a ratio of the axial length to the first lateral width being between 201.3 and 215.3. An aircraft system is also disclosed.

Abstract: An air-liquid heat exchanger assembly for an environmental control system of an aircraft is provided including a heat exchanger configured to transfer heat between air and a liquid. The heat exchanger includes a first chamber and a second chamber arranged generally in series relative to a flow of the liquid. A movable bypass valve is operably coupled to a controller. The bypass valve is positioned between and coupled to the first chamber and the second chamber. The bypass valve is configured to control the flow of the liquid through the second chamber and a bypass conduit in response to measured operating conditions of the assembly.

Abstract: A multi-chamber heat exchanger header includes a header housing and an insert. The header housing has a first wall and a second wall generally opposite the first wall where the first and second walls define a track. The insert is positioned to engage with the track such that the insert separates the header into first and second manifold chambers. A method for forming a multi-chamber heat exchanger header includes extruding a header housing having first and second manifold chambers and a track, positioning an insert in the header housing to engage with the track, and welding or brazing the insert to the header housing.