Abstract: A ram air fan outer housing for directing air from a ram air fan rotor and air from a ram air bypass into a ram air fan outlet. The outer housing includes an outer cylinder and a plenum connected at a joint region. The outer cylinder and the plenum are made of a laminate stacking sequence of at least four adjacent layers of plain-weave carbon-fiber fabric. Each layer of the stacking sequence has a weave orientation such that a first layer and a fourth layer are oriented forty-five degrees from each of a second layer and a third layer. The joint region is made of at least eight adjacent layers of plain-weave carbon-fiber fabric. The joint region laminate stacking sequence is formed by interleaving the four adjacent outer cylinder layers in the joint region with the four adjacent plenum layers in the joint region.

Abstract: A ram air fan inner housing for a ram air fan assembly comprises a center body housing, an end cup attached to the center body housing, and a perforated cone. The perforated cone is attached to the center body housing and the end cup such that the perforated cone extends away from the center body housing and radially inward toward an axis of the inner housing.

Abstract: A thrust shaft for a fan has a shaft body with an enlarged disk adjacent one axial end to provide a rotating surface in a pair of thrust bearings. A first cylindrical portion extends from the disk in a first direction, and a second cylindrical portion extending from the disk in a second opposed direction. The second cylindrical portion has a hollow bore, and there are a plurality of holes extending through the second cylindrical portion to communicate an outer periphery with the bore. A ratio of the diameter of the bore to a diameter of the plurality of air holes is between 6.60 and 7.00. A ratio of an overall length of the second cylindrical portion, and a distance from a face of the enlarged disk to a center of the holes is between 14.4 and 15.2. A thrust bearing assembly, a fan, a cabin air supply system, and a method are also disclosed.

Abstract: An air cycle machine includes a bearing housing with a shaft bore. A rotor shaft is arranged in the shaft bore and includes knife edges extending from the rotor shaft. A seal engages the shaft bore and includes an outer diameter and an inner diameter providing a seal land axially aligned with the knife edges. A radial clearance between the seal land and the knife edges is nominally 0.006 inch. The inner diameter is arranged between lateral sides of the seal that define a width. In one example, a tapered surface extending at an angle relative to the outer diameter from the lateral side to the seal land, the tapered surface facing the large end. The outer diameter to the inner diameter provides a first ratio of 1.25-1.28, and the inner diameter to the width provides a second ratio of 4.33-5.58.

Abstract: An air cycle machine including a housing with a compressor housing portion and a turbine housing portion secured to one another by fasteners. The compressor and turbine housing portions each provide a surface. An insulator plate is provided between and engages the surfaces. The fasteners extend through circumferentially arranged holes in the insulator plate. The insulator plate has an axial width, an inner diameter and an outer diameter. The outer diameter to the inner diameter provides a first ratio of 1.19-1.21, and the inner diameter to the width provides a second ratio of 53-59. In one example, the insulator plate is a composite structure constructed from 9-12 carbon fiber laminations with each layer having directional carbon fibers oriented transversely relative to the carbon fibers of an adjacent layer.

Abstract: A thrust shaft for a fan has a shaft body with an enlarged disk adjacent one axial end to provide a rotating surface in a pair of thrust bearings. A first cylindrical portion extends from the disk in a first direction, and a second cylindrical portion extending from the disk in a second opposed direction. The second cylindrical portion has a hollow bore, and there are a plurality of holes extending through the second cylindrical portion to communicate an outer periphery with the bore. A ratio of the diameter of the bore to a diameter of the plurality of air holes is between 6.60 and 7.00. A ratio of an overall length of the second cylindrical portion, and a distance from a face of the enlarged disk to a center of the holes is between 14.4 and 15.2. A thrust bearing assembly, a fan, a cabin air supply system, and a method are also disclosed.

Abstract: A ram air fan outer housing for directing air from a ram air fan rotor and air from a ram air bypass into a ram air fan outlet. The outer housing includes an outer cylinder and a plenum connected at a joint region. The outer cylinder and the plenum are made of a laminate stacking sequence of at least four adjacent layers of plain-weave carbon-fiber fabric. Each layer of the stacking sequence has a weave orientation such that a first layer and a fourth layer are oriented forty-five degrees from each of a second layer and a third layer. The joint region is made of at least eight adjacent layers of plain-weave carbon-fiber fabric. The joint region laminate stacking sequence is formed by interleaving the four adjacent outer cylinder layers in the joint region with the four adjacent plenum layers in the joint region.

Abstract: A ram air fan inner housing for a ram air fan assembly comprises a center body housing, an end cup attached to the center body housing, and a perforated cone. The perforated cone is attached to the center body housing and the end cup such that the perforated cone extends away from the center body housing and radially inward toward an axis of the inner housing.

Abstract: An air cycle machine includes a bearing housing with a shaft bore. A rotor shaft is arranged in the shaft bore and includes knife edges extending from the rotor shaft. A seal engages the shaft bore and includes an outer diameter and an inner diameter providing a seal land axially aligned with the knife edges. A radial clearance between the seal land and the knife edges is nominally 0.006 inch. The inner diameter is arranged between lateral sides of the seal that define a width. In one example, a tapered surface extending at an angle relative to the outer diameter from the lateral side to the seal land, the tapered surface facing the large end. The outer diameter to the inner diameter provides a first ratio of 1.25-1.28, and the inner diameter to the width provides a second ratio of 4.33-5.58.

Abstract: An air cycle machine including a housing with a compressor housing portion and a turbine housing portion secured to one another by fasteners. The compressor and turbine housing portions each provide a surface. An insulator plate is provided between and engages the surfaces. The fasteners extend through circumferentially arranged holes in the insulator plate. The insulator plate has an axial width, an inner diameter and an outer diameter. The outer diameter to the inner diameter provides a first ratio of 1.19-1.21, and the inner diameter to the width provides a second ratio of 53-59. In one example, the insulator plate is a composite structure constructed from 9-12 carbon fiber laminations with each layer having directional carbon fibers oriented transversely relative to the carbon fibers of an adjacent layer.

Abstract: A fan rotor ring for an air cycle machine includes a ring body that defines a main bore having a main bore diameter and central axis. An annular flange extends axially from the ring body over a length and defines a fan ring bore having a fan ring bore inner diameter. A ratio of the fan ring bore inner diameter to the length of the annular flange is 1.63-1.69.