Abstract: A method for forming a thermoplastic part includes sulfonating a thermoplastic film by exposing the thermoplastic film to a sulfonation fluid to form a sulfonated thermoplastic film and forming the thermoplastic part with a plurality of stacked thermoplastic film layers. The plurality of stacked thermoplastic film layers include at least one sulfonated thermoplastic film layer of the sulfonated thermoplastic film and a plurality of unsulfonated thermoplastic film layers. The at least one sulfonated thermoplastic film layer forms a first exterior thermoplastic film surface of the thermoplastic part.

Abstract: An environmental control system of a vehicle includes an inlet configured to receive a medium, an outlet for receiving a conditioned form of the medium. A first portion of the medium at the outlet is to be provided to a cabin of the vehicle, and a thermodynamic device is in fluid communication with the inlet. The thermodynamic device includes a compressor, a first turbine, and a second turbine, operably coupled by a shaft. At least a portion of the medium is provided to the compressor, the first turbine and the second turbine in series. An air-liquid heat exchanger is positioned fluidly downstream of the second turbine such that the medium output from the second turbine exchanges thermal energy with a flow of liquid at the liquid-air heat exchanger. The first portion of the medium is output to the cabin downstream of the liquid-air heat exchanger.

Abstract: A coalescing tube bundle elbow for a water collector includes an inlet end, an outlet end, and a body section fluidly connecting the inlet and outlet ends. The inlet end can receive a fluid flow in an at least partially gaseous state in an incoming direction. The outlet end can discharge the fluid flow in an at least partially liquid state in an outgoing direction. The body section can condense at least a portion of the fluid flow from a gaseous state into a liquid state. The body section includes channels which are defined by channel walls and which extend along the body section from the inlet end to the outlet end, and has a curved profile such that the outgoing direction of the fluid flow is not parallel to the incoming direction of the fluid flow.

Abstract: An air cycle system for a gas turbine engine includes a heat exchanger having an air cycle inlet. An air cycle machine includes an air cycle machine outlet and an annular flexible interface coupling connecting the air cycle inlet to the outlet. The flexible interface coupling includes a receiving portion having a flared region across which a diameter of a heat exchanger portion increases and a landing portion across which the diameter of the heat exchanger portion is maintained. An air cycle machine portion is received in the receiving portion and includes an outlet flange and a diffuser radially inward of the outlet flange. The outlet flange includes a radially outward facing surface contacting a radially inward facing surface of the landing portion. The diffuser is configured to move axially and radially relative to the outlet flange.

Abstract: A water separator for use in an environmental control system of an aircraft includes a coalescing channel having a curved housing. The coalescing channel has a hollow interior. A coalescing insert is arranged within the hollow interior of the coalescing channel. The coalescing insert has an upstream end, a downstream end, and plurality of fluidly distinct flow channels extending between the upstream end and the downstream end such that the plurality of fluidly distinct flow channels receive a flow of medium in parallel.

Abstract: Aircraft air cycle machines include a first stage turbine, a second stage turbine that receives air from the first stage turbine, and a duct arranged between the first stage turbine and the second stage turbine. A circular finned coalescer is arranged within the duct and includes a central body, a first fin layer wrapped about the central body, a first parting sheet wrapped about the first fin layer, and a second fin layer wrapped about the first parting sheet. Each of the fin layers include a plurality of fin elements and channels are defined between circumferentially adjacent fin elements of each of the first and second fin layers. The channels are tortuous channels such that moisture carried on a flow through the channels will impinge upon surfaces of the fin elements and coalesce into water droplets.

Abstract: Aircraft air cycle machines include a first stage turbine, a second stage turbine, and a duct arranged between the first stage turbine and the second stage turbine. A plate-fin coalescer is arranged along the duct. The plate-fin coalescer includes a housing, a first fin layer arranged within the housing, a second fin layer arranged within the housing, and a first parting sheet arranged between the first fin layer and the second fin layer. Each of the first fin layer and the second fin layer include a plurality of fin elements arranged in substantially parallel orientation relative an axis through the housing, and channels are defined between adjacent fin elements of the plurality of fin elements of each of the first fin layer and the second fin layer. Moisture carried on a flow through the channels will impinge upon surfaces of the fin elements and coalesce into water droplets for removal.

Abstract: 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.

Abstract: An environmental control system includes a first water collector having a first drain line and a second water collector having a second drain line. The first drain line is fluidly connected to the second drain line. The environmental control system includes also includes at least one spray nozzle. An outlet of the second drain line is fluidly connected to the at least one spray nozzle.

Abstract: A lattice coalescer is provided and includes an architected lattice having a cylindrical shape with an upstream end and a downstream end. The architected lattice includes a solid outer body and an interior body disposed within the solid outer body and substantially filled in three dimensions with tessellated unit cells. The tessellated unit cells are arranged with respect to one another in a cell map such that a fog-laden airflow moving through the architected lattice from the upstream end to the downstream end exhibits a pressure drop of 2 psi or less and formation of water droplets of 10-40 microns.

Abstract: An environmental control system of a vehicle includes a compressor having a compressor inlet configured to receive a first medium and a compressor outlet. A compressed first medium is provided at the compressor outlet. A conduit is configured to receive a second medium and a heat exchanger is mounted to the compressor. The heat exchanger is fluidly connected to a portion of the compressor and to the conduit.

Abstract: An environmental control system includes a component having a component inlet and a component outlet and a flow path fluidly connected to the component inlet and the component outlet. The flow path includes a turn upstream from the component inlet. At least one flow diverter element is arranged within the flow path between the turn and the component outlet. The at least one flow diverter element is positioned to uniformly distribute a flow across the component inlet.

Abstract: An air cycle system for a gas turbine engine includes a heat exchanger having an air cycle inlet. An air cycle machine includes an air cycle machine outlet and an annular flexible interface coupling connecting the air cycle inlet to the outlet. The flexible interface coupling includes a receiving portion having a flared region across which a diameter of a heat exchanger portion increases and a landing portion across which the diameter of the heat exchanger portion is maintained. An air cycle machine portion is received in the receiving portion and includes an outlet flange and a diffuser radially inward of the outlet flange. The outlet flange includes a radially outward facing surface contacting a radially inward facing surface of the landing portion. The diffuser is configured to move axially and radially relative to the outlet flange.

Abstract: A method of monitoring aircraft including removing a conical collector through a cabin exhaust valve of the aircraft wherein ambient cabin air has been driven from the cabin over a reagent fluid within the conical collector in order to collect a representative sample of the cabin air within the reagent fluid.

Abstract: A water separator includes an outer annular passage extending along a central longitudinal axis of water separator to direct an airflow along a first direction, and an inner annular passage located radially inboard of the outer annular passage and coaxial with the outer annular passage to direct the airflow along a second direction. A coalescer is located along the outer annular passage to coalesce water in the airflow. A water collector is located along the inner annular passage to collect the water. An airflow outlet is located downstream of the water collector through which the airflow exits the water separator.

Abstract: A heat exchanger includes a plurality of heat exchanger plates stacked along a stacking axis defining a plurality of first pathways through which a first fluid is directed, and a plurality of fins located between adjacent first pathways of the plurality of first pathways. The plurality of fins at least partially define a plurality of second pathways through which a second fluid is directed. The heat exchanger plates are formed from a sheet material, and the plurality of fins are formed from one or more additive manufacturing processes.

Abstract: A heat exchanger includes a heat exchanger body having a plurality of heat exchanger tubes, an inlet manifold connected to the heat exchanger body and configured to distribute a flow of fluid from a fluid inlet of the inlet manifold to the plurality of heat exchanger tubes, and an outlet manifold connected to the heat exchanger body and configured to collect the flow of fluid from the plurality of heat exchanger tubes and direct the flow of fluid through a fluid outlet. The heat exchanger body is formed via one or more additive manufacturing processes, and at least one of the inlet manifold and the outlet manifold is formed via one or more subtractive manufacturing processes.

Abstract: A water separator for use in an environmental control system of an aircraft includes a coalescing channel having a curved housing. The coalescing channel has a hollow interior. A coalescing insert is arranged within the hollow interior of the coalescing channel. The coalescing insert has an upstream end, a downstream end, and plurality of fluidly distinct flow channels extending between the upstream end and the downstream end such that the plurality of fluidly distinct flow channels receive a flow of medium in parallel.

Abstract: An environmental control system includes a first water collector having a first drain line and a second water collector having a second drain line. The first drain line is fluidly connected to the second drain line. The environmental control system includes also includes at least one spray nozzle. An outlet of the second drain line is fluidly connected to the at least one spray nozzle.

Abstract: An environmental control system of an aircraft includes a primary heat exchanger, a secondary heat exchanger and an air cycle machine. The air cycle machine includes a compressor fluidly coupled to an outlet of the primary heat exchanger and an inlet of the secondary heat exchanger, a dehumidification system arranged in fluid communication with the outlet of the secondary heat exchanger, a first turbine fluidly coupled to an outlet of the secondary heat exchanger and optionally a second turbine disposed downstream of the first turbine that receives air from the first turbine in a normal mode a first humidity sensor disposed fluidly between the first turbine and the second turbine that measures humidity of air that has left the first turbine as it enters the second turbine in the normal mode.