SBIR-STTR Award

Additively Manufactured, Structurally-Integrated, Passive Two-Phase Heat Sink for Electrified Aircraft Propulsion Systems
Award last edited on: 1/23/2023

Sponsored Program
SBIR
Awarding Agency
NASA : GRC
Total Award Amount
$864,021
Award Phase
2
Solicitation Topic Code
A1.04
Principal Investigator
Ben Alexander

Company Information

ThermAvant Technologies LLC (AKA: Thermavant)

2508 Paris Road
Columbia, MO 65202
   (573) 397-6912
   info@thermavant.com
   www.thermavant.com
Location: Multiple
Congr. District: 04
County: Boone

Phase I

Contract Number: 80NSSC21C0339
Start Date: 5/19/2021    Completed: 11/19/2021
Phase I year
2021
Phase I Amount
$124,990
In an effort provide significant improvements in aircraft fuel/energy economy and emissions, turbo-, hybrid, and fully electric aircraft are being developed to utilize high-efficiency electric propulsion systems (EAPs). To enable these systems, thermal management systems (TMS) are needed which can be scaled to the power ranges required while providing the efficiency and power density that makes these technologies compelling. ThermAvant Technologies, LLC proposes a novel TMS based on the company’s flagship technology: structurally embedded oscillating heat pipes (OHPs). The OHP is a passive two-phase heat transfer device that relies on concentrated heat loads to passively drive a working fluid through a high-density array of microchannels, which are ideal for embedding within thin structures such as a structural skin. Without the need for the wick structures of their conventional predecessor heat pipes, OHPs are especially well suited for integration into materials within which it is difficult to construct traditional heat pipes. In addition to the absence of a wick structure, the OHP’s unique I-beam architecture (formed by the walls between the microchannels) enables the structure to be multifunctional and serve as a structural member with integrated passive thermal management. Furthermore, through the use of additive manufacturing technology, these devices can be deeply integrated within the structure of EAP systems. These high-conductance, embedded devices will provide significant improvements to power density by both decreasing thermal impedance and reducing mass, and provide additional design freedom for the layout of heat generating components within the EAP system while still providing improved thermal performance. To provide further performance optimization under both transient and steady-state conditions, energy storage devices will be evaluated to independently optimize the conductive and capacitive properties of the heat sink. Potential NASA Applications (Limit 1500 characters, approximately 150 words): NASA's Electrified Aircraft Propulsion project resides within the Aeronautics Research Mission Directorate Strategic Thrust 4: Transition to Low-Carbon Propulsion. In particular, within Thrust 4, this technology has direct application to the X-57 program, as well as to the Revolutionary Vertical Lift Technology project. Beyond these applications, this technology also has application to the cooling concepts for hybrid electric aircraft that are being investigated through the HEATheR program. Potential Non-NASA Applications (Limit 1500 characters, approximately 150 words): ThermAvant is aware of a number of applications that could potentially use such additively manufactured, thermal devices, e.g. commercial manned/unmanned aerial vehicles, and various commercial space applications. ThermAvant believes there are a multi-million-dollar annual revenue opportunities within each of these industries if the multifunctional prototypes are able to successfully be produced. Duration: 6

Phase II

Contract Number: 80NSSC22CA148
Start Date: 4/28/2022    Completed: 4/27/2024
Phase II year
2022
Phase II Amount
$739,031
To provide significant improvements in aircraft fuel/energy economy and emissions, electric aircraft are being developed with a current commercial market of $7.9 Billion in 2021 with predicted growth to $27.7 Billion by 2030. Per NASA 2020-I SBIR A1.04 Electrified Aircraft Propulsion (EAP), thermal management systems (TMS) are needed which can be scaled to high power required to make EAP technologies compelling. In Phase I, ThermAvant (TAT) demonstrated a novel additively manufactured (AM) TMS based on company's flagship product the structurally embedded Oscillating Heat Pipe (OHP). The key advantages of this AM-OHP are (1) Exceptional passive thermal transport capacity (> 4kW/kg) as compared with alternative solutions, (2) 50% mass reduction compared with solid control, significantly more when compared with active cooling alternatives, (3) >3x reduction in design cycle and manufacturing time, (4) performance independent of gravity, and (5) thermal performance insensitivity to variable distribution of heat sources (electronics) provides flexibility to EAP electronic systems design. Potential NASA Applications (Limit 1500 characters, approximately 150 words): Advanced Air Transport Technology (AATT) program within Aero Research Mission Directorate (ARMD) NASA JSC Potential Non-NASA Applications (Limit 1500 characters, approximately 150 words): Minute Man Missile Small eVTOL aircraft Duration: 24