Abstract: A bearing housing for a two-wheel air cycle machine includes a first housing portion, a second housing portion, a third housing portion, and a journal bearing bore. The first housing portion is centered around an axis and has a first side and a second side. The second side is positioned axially away from the first side. The second housing portion is centered around the axis and has a first side and a second side. The second side is positioned axially away from the first side. The first side of the second housing portion connects to the second side of the first housing portion. The third housing portion is centered around the axis and has a first side and a second side. The second side is positioned axially away from the first side. The first side of the third housing portion connects to the second side of the second housing portion. The journal bearing bore is centered axially with in the bearing housing and has a diameter of D1.

Abstract: A turbine housing for a two-wheel air cycle machine includes a first side of the turbine housing, a second side of the turbine housing, a central axis, an outer housing portion, an inner housing portion, a plurality of struts between the inner housing portion and the outer housing portion and a plurality of cooling slots between the plurality of supports. The outer housing portion includes an inner surface, an outer surface, a cooling inlet extending from the outer surface of the outer housing portion and a cooling outlet opposite the cooling inlet and extending from the outer surface of the outer housing portion. The inner housing portion includes a thrust bearing support surface substantially parallel to the second side of the turbine housing and a journal bearing bore extending between the first side of the turbine housing and the thrust bearing support surface.

Abstract: An outlet manifold is provided and includes an outlet portion having first and second sides and an inlet portion to which the outlet portion is fluidly coupled. The inlet portion has first and second sides corresponding to the first and second sides of the outlet portion. Each of the first and second sides of the inlet portion includes one or more tubular members connectable with corresponding tube joints and a mixing chamber fluidly interposed between each of the one or more tubular members and the outlet portion.

Abstract: A turbine housing for a two-wheel air cycle machine includes a first side of the turbine housing, a second side of the turbine housing, a central axis, an outer housing portion, an inner housing portion, a plurality of struts between the inner housing portion and the outer housing portion and a plurality of cooling slots between the plurality of supports. The outer housing portion includes an inner surface, an outer surface, a cooling inlet extending from the outer surface of the outer housing portion and a cooling outlet opposite the cooling inlet and extending from the outer surface of the outer housing portion. The inner housing portion includes a thrust bearing support surface substantially parallel to the second side of the turbine housing and a journal bearing bore extending between the first side of the turbine housing and the thrust bearing support surface.

Abstract: A bearing housing for a two-wheel air cycle machine includes a first housing portion, a second housing portion, a third housing portion, and a journal bearing bore. The first housing portion is centered around an axis and has a first side and a second side. The second side is positioned axially away from the first side. The second housing portion is centered around the axis and has a first side and a second side. The second side is positioned axially away from the first side. The first side of the second housing portion connects to the second side of the first housing portion. The third housing portion is centered around the axis and has a first side and a second side. The second side is positioned axially away from the first side. The first side of the third housing portion connects to the second side of the second housing portion. The journal bearing bore is centered axially with in the bearing housing and has a diameter of D1.

Abstract: An outlet manifold is provided and includes an outlet portion having first and second sides and an inlet portion to which the outlet portion is fluidly coupled. The inlet portion has first and second sides corresponding to the first and second sides of the outlet portion. Each of the first and second sides of the inlet portion includes one or more tubular members connectable with corresponding tube joints and a mixing chamber fluidly interposed between each of the one or more tubular members and the outlet portion.

Abstract: An outlet manifold is provided and includes an outlet portion having first and second sides and an inlet portion to which the outlet portion is fluidly coupled. The inlet portion has first and second sides corresponding to the first and second sides of the outlet portion. Each of the first and second sides of the inlet portion includes one or more tubular members connectable with corresponding tube joints and a mixing chamber fluidly interposed between each of the one or more tubular members and the outlet portion.

Abstract: A fan and compressor housing for an air cycle machine includes a fan inlet disposed around a center axis of the housing and having a fan inlet mounting flange, a compressor outlet having a compressor outlet mounting flange, and a compressor inlet having a compressor inlet mounting flange. The fan inlet mounting flange has a pinhole disposed thereon configured to receive a pin from a fan inlet diffuser housing and a fan inlet counterbore configured to receive a mating component from the fan inlet diffuser housing. The compressor outlet mounting flange has a compressor outlet counterbore configured to receive a first mating component from a condenser/reheater. The compressor inlet mounting flange has a compressor inlet counterbore configured to receive a second mating component from the condenser/reheater.

Abstract: An outlet manifold is provided and includes an outlet portion having first and second sides and an inlet portion to which the outlet portion is fluidly coupled. The inlet portion has first and second sides corresponding to the first and second sides of the outlet portion. Each of the first and second sides of the inlet portion includes one or more tubular members connectable with corresponding tube joints and a mixing chamber fluidly interposed between each of the one or more tubular members and the outlet portion.

Abstract: A fan inlet diffuser housing includes a housing body of composite material and includes a heat exchanger interface portion positioned between an ejector housing portion and a bypass housing portion. A first transition region is formed between the heat exchanger interface portion and the ejector housing portion including an air cycle machine end reinforcement patch proximate to a heat exchanger interface. The air cycle machine end reinforcement patch includes a first patch thickness and a second patch thickness, and a ratio of the first patch thickness to the second patch thickness is between 2.02 and 3.11. An ejector is formed having an ejector gap width between a nozzle portion and a diffuser portion within the ejector housing portion of the housing body. The diffuser portion has a downstream ejector gap width, and a ratio of the downstream ejector gap width to the ejector gap width is between 4.62 and 5.01.

Abstract: A method and system to provide a fan inlet diffuser housing including a housing body formed from a composite material, wherein the composite material includes a base fiberglass material having a first conductivity, a conductive material having a second conductivity, wherein the second conductivity is greater than the first conductivity, and a binder that bonds the base fiberglass material and the conductive material.

Abstract: A fan and compressor housing for an air cycle machine includes a fan inlet disposed around a center axis of the housing and having a fan inlet mounting flange, a compressor outlet having a compressor outlet mounting flange, and a compressor inlet having a compressor inlet mounting flange. The fan inlet mounting flange has a pinhole disposed thereon configured to receive a pin from a fan inlet diffuser housing and a fan inlet counterbore configured to receive a mating component from the fan inlet diffuser housing. The compressor outlet mounting flange has a compressor outlet counterbore configured to receive a first mating component from a condenser/reheater. The compressor inlet mounting flange has a compressor inlet counterbore configured to receive a second mating component from the condenser/reheater.

Abstract: A fan rotor blade extending radially from a hub is described. The fan rotor blade may include first surface and a second surface, where the first surface and second surfaces are respectively defined by a set of X-coordinates, Y-coordinates and Z-coordinates. The X, Y and Z coordinates can be set out in any of Tables T-1, T-2, E-1, and E-2. The X, Y, and Z-coordinates can also be scaled by a predetermined factor, with the X-coordinates are oriented in a tangential direction, the Z-coordinates are oriented in an axial direction, and the Y-coordinates are oriented in a radial direction.

Abstract: A flow duct able to be connected to a ram outlet header includes a band having an annular shape and a glove connected to the band. The glove can include a first end that is annular in shape and connected to the band, a body that is curved and has a substantially U-shaped cross section with a first opening, and a second end that has a substantially U-shaped cross section and a second opening that is an extension of the first opening.

Abstract: A fan housing for an air cycle machine includes a fan exit flow passage and a ring disposed around a center axis of the fan housing and disposed around the fan exit flow passage. The ring includes a first end disposed axially opposite a second end and a guide surface facing radially inward relative the center axis and formed between the first end and the second end. The ring also includes a shelf disposed radially inward from the guide surface. The shelf includes a stop surface extending radially and disposed axially between the second end and the guide surface. The shelf also includes a shelf surface facing radially outward relative the center axis and extending axially between the first end and the stop surface.

Abstract: A fan inlet diffuser housing includes a housing body of composite material and includes a heat exchanger interface portion positioned between an ejector housing portion and a bypass housing portion. A first transition region is formed between the heat exchanger interface portion and the ejector housing portion including an air cycle machine end reinforcement patch proximate to a heat exchanger interface. The air cycle machine end reinforcement patch includes a first patch thickness and a second patch thickness, and a ratio of the first patch thickness to the second patch thickness is between 2.02 and 3.11. An ejector is formed having an ejector gap width between a nozzle portion and a diffuser portion within the ejector housing portion of the housing body. The diffuser portion has a downstream ejector gap width, and a ratio of the downstream ejector gap width to the ejector gap width is between 4.62 and 5.01.

Abstract: A method and system to provide a fan inlet diffuser housing including a housing body formed from a composite material, wherein the composite material includes a base fiberglass material having a first conductivity, a conductive material having a second conductivity, wherein the second conductivity is greater than the first conductivity, and a binder that bonds the base fiberglass material and the conductive material.

Abstract: A turbine inlet housing has a main housing body extending about a central axis. An inlet duct delivers air into a cavity within the main housing body. Bolt hole bosses are formed on a downstream face of the inlet housing to receive bolts to secure an outlet housing to the inlet housing. A plurality of the bosses have a ramped surface which extends radially outwardly for a greater extent than a second plurality of bosses. The plurality of ramped bosses extend between the downstream face and the duct. The ramped bosses have a forward boss portion, and a ramped surface at an angle of between 50 and 54 degrees extending from an upstream end of the forward boss portion. A curved surface curves from an upstream end of the ramped surface to merge into the duct. A turbine stage and air cycle machine are also disclosed and claimed.

Abstract: A fan shroud for an air cycle machine includes a tubular body extending axially between a first end and a second end of the shroud along a center axis of the fan shroud. A flange extends radially outward from the tubular body of the shroud at the first end of the shroud. At least one mounting hole extends through the flange. A sight hole extends through the flange and is positioned radially inward from the at least one mounting hole relative the center axis.

Abstract: A ram air fan housing includes an outer cylindrical housing portion centered on a central axis, with a first end and a second end positioned axially away from the first end. The ram air fan housing also includes an inner cylindrical housing portion centered on a central axis, with a first end and a second end positioned axially away from the first end. The first end of the outer cylindrical housing portion is connected to the first end of the inner cylindrical housing portion with a disk portion. The ram air fan housing also includes a first drain hole in the outer cylindrical housing portion adjacent to the second end of the outer cylindrical housing portion.