Method of manufacturing a heat transfer system for aircraft structures

Abstract

A method of manufacturing a heat transfer system is provided that includes preparing a heat conducting array by perforating at least a portion of the heat conducting array, placing the heat conducting array around foam elements, and forming the structural assembly under heat and pressure. A material of the foam elements extends through the perforated portion of the heat conducting array during the forming step.

What is claimed is: 
     
         1 . A method of manufacturing a heat transfer system comprising:
 preparing a heat conducting array by perforating at least a portion of the heat conducting array;   placing the heat conducting array around foam elements; and   forming the structural assembly under heat and pressure,   
       wherein a material of the foam elements extends through the perforated portion of the heat conducting array during the forming step. 
     
     
         2 . The method according to  claim 1 , wherein the heat conducting array is prepared as a continuous piece. 
     
     
         3 . The method according to  claim 1 , wherein the heat conducting array is prepared as separate pieces. 
     
     
         4 . The method according to  claim 1 , wherein the structural assembly is cured by at least one of a room temperature and standard atmospheric pressure cure, and a vacuum autoclave cure. 
     
     
         5 . The method according to  claim 1 , wherein the heat conducting array is a pyrolytic graphite sheet (PGS) material. 
     
     
         6 . The method according to  claim 1 , wherein the heat conducting array defines at least one upper cap, at least one lower cap, and a wall portion extending between at least one upper cap and at least one lower cap when placed around the foam elements, and the wall portion is perforated. 
     
     
         7 . The method according to  claim 1  further comprising placing a heat conducting spreader along one surface area of the foam elements prior to the forming step. 
     
     
         8 . The method according to  claim 1 , wherein the forming step is carried out in a press. 
     
     
         9 . The method according to  claim 1 , wherein the foam elements are polystyrene. 
     
     
         10 . An air vehicle having a component manufactured according to the method  claim 1 . 
     
     
         11 . A method of manufacturing a heat transfer system comprising forming a structural assembly under heat and pressure, the structural assembly comprising a heat conducting array defining a plurality of apertures placed around foam elements, wherein a material of the foam elements extends through the perforated portion of the heat conducting array during the forming step. 
     
     
         12 . The method according to  claim 11  further comprising:
 placing a lower skin over one surface area of the foam elements; and 
 placing an upper skin over an opposite surface area of the foam elements prior to the forming step. 
 
     
     
         13 . The method according to  claim 11 , wherein the heat conducting array is prepared as a continuous piece. 
     
     
         14 . The method according to  claim 11 , wherein the heat conducting array is prepared as separate pieces. 
     
     
         15 . The method according to  claim 11 , wherein the structural assembly is cured by at least one of a room temperature and standard atmospheric pressure cure, and a vacuum autoclave cure. 
     
     
         16 . The method according to  claim 11 , wherein the heat conducting array defines at least one upper cap, at least one lower cap, and a wall portion extending between at least one upper cap and at least one lower cap when placed around the foam elements, and the wall portion is perforated. 
     
     
         17 . The method according to  claim 11 , wherein the forming step is carried out in a press. 
     
     
         18 . An air vehicle having a component manufactured according to the method  claim 11 . 
     
     
         19 . A method of manufacturing a structural assembly, the structural assembly comprising a heat conducting array defining a plurality of apertures placed around foam elements, the method comprising forming the structural assembly under heat and pressure, wherein a material of the foam elements extends through the perforated portion of the heat conducting array during the forming step. 
     
     
         20 . An air vehicle having a component manufactured according to the method  claim 19 .