Gas turbine engine heat exchangers and methods of assembling the same

Abstract

A heat exchanger assembly for use in a gas turbine engine includes a bypass valve and at least one body portion. The body portion includes at least one de-congealing inlet channel in flow communication with the bypass valve, a plurality of cooling channels in flow communication with the bypass valve and the at least one de-congealing inlet channel, and at least one de-congealing outlet channel in flow communication with the bypass valve and the at least one de-congealing inlet channel. The bypass valve is configured to deliver a fluid between the at least one de-congealing inlet channel and the plurality of cooling channels during a first mode of operation to facilitate reducing a temperature of the fluid. The bypass valve is further configured to deliver the fluid between the at least one de-congealing inlet channel and the at least one de-congealing outlet channel during a second mode of operation.

What is claimed is: 
     
         1 . A heat exchanger assembly for use in a gas turbine engine including a core gas turbine engine having an axis of rotation, a splitter circumscribing the core gas turbine engine, a fan assembly positioned upstream of the core gas turbine engine, a fan casing substantially circumscribing the fan assembly, and a bypass duct that is defined between the fan casing and the splitter, said heat exchanger assembly comprising:
 a bypass valve; and   at least one body portion including:
 at least one de-congealing inlet channel in flow communication with said bypass valve; 
 a plurality of cooling channels in flow communication with said bypass valve and said at least one de-congealing inlet channel, wherein said bypass valve is configured to deliver a fluid between said at least one de-congealing inlet channel and said plurality of cooling channels during a first mode of operation to facilitate reducing a temperature of the fluid; and 
 at least one de-congealing outlet channel in flow communication with said bypass valve and said at least one de-congealing inlet channel, wherein said bypass valve is configured to deliver the fluid between said at least one de-congealing inlet channel and said at least one de-congealing outlet channel during a second mode of operation. 
   
     
     
         2 . The heat exchanger assembly in accordance with  claim 1 , wherein said heat exchanger assembly is coupled to a radially interior surface of the fan casing such that said heat exchanger assembly is positioned upstream of the fan assembly. 
     
     
         3 . The heat exchanger assembly in accordance with  claim 1 , wherein said heat exchanger assembly is coupled to a radially exterior surface of the splitter such that the heat exchanger assembly is positioned within the bypass duct. 
     
     
         4 . The heat exchanger assembly in accordance with  claim 1  further comprising a plurality of cooling fins extending radially from at least one exterior surface of said body portion, said plurality of cooling channels configured to receive a flow of air to facilitate reducing a temperature of the fluid flowing through said plurality of cooling channels during the first mode of operation. 
     
     
         5 . The heat exchanger assembly in accordance with  claim 4 , wherein said plurality of cooling channels are positioned radially outward of said at least one de-congealing inlet channel and said at least one de-congealing outlet channel and said plurality of cooling channels are positioned radially inward of said plurality of cooling fins. 
     
     
         6 . The heat exchanger assembly in accordance with  claim 4 , wherein said plurality of cooling fins are formed integrally with said body portion. 
     
     
         7 . The heat exchanger assembly in accordance with  claim 1  further comprising:
 an inlet in flow communication with said at least one de-congealing inlet channel at a first end of said heat exchanger assembly; and 
 an outlet in flow communication with said at least one de-congealing outlet channel at said first end of said heat exchanger assembly, wherein said bypass valve is positioned at an opposing second end of said heat exchanger assembly. 
 
     
     
         8 . The heat exchanger assembly in accordance with  claim 1 , wherein said bypass valve is configured to deliver the fluid to said at least one de-congealing outlet channel when the fluid reaches a pre-determined temperature. 
     
     
         9 . The heat exchanger assembly in accordance with  claim 1 , wherein said bypass valve is configured to deliver the fluid to said at least one de-congealing outlet channel and said plurality of cooling channels during the second mode of operation. 
     
     
         10 . The heat exchanger assembly in accordance with  claim 1 , wherein said at least one de-congealing outlet channel is proximate to said plurality of cooling channels such that fluid flow through said at least one de-congealing outlet channel during the second mode of operation facilitates de-congealing an amount of fluid within said plurality of cooling channels. 
     
     
         11 . A method for assembling a gas turbine engine including an axis of rotation, the method comprising:
 providing a fan casing that substantially circumscribes the gas turbine engine;   providing a heat exchanger assembly including:
 a bypass valve; and 
 at least one body portion including:
 at least one de-congealing inlet channel in flow communication with said bypass valve; 
 a plurality of cooling channels in flow communication with said bypass valve and said at least one de-congealing inlet channel, wherein said bypass valve is configured to deliver a fluid between said at least one de-congealing inlet channel and said plurality of cooling channels during a first mode of operation to facilitate reducing a temperature of the fluid; and 
 at least one de-congealing outlet channel in flow communication with said bypass valve and said at least one de-congealing inlet channel, wherein said bypass valve is configured to deliver the fluid between said at least one de-congealing inlet channel and said at least one de-congealing outlet channel during a second mode of operation; and 
 
   coupling the heat exchanger assembly to the fan casing.   
     
     
         12 . The method according to  claim 11  further comprising coupling a plurality of cooling fins to a radially exterior surface of the body portion such that the plurality of cooling fins are configured to receive a flow of air to facilitate reducing a temperature of the fluid flowing through the plurality of cooling channels during the first mode of operation 
     
     
         13 . The method according to  claim 12 , wherein coupling the heat exchanger assembly to the fan casing further comprises coupling the heat exchanger assembly within a recess in the fan casing such that the at least one radially exterior surface is flush with a radially interior surface of the fan casing such that only the plurality of cooling fins are exposed to the flow of air. 
     
     
         14 . The method according to  claim 13  further comprising:
 positioning the plurality of cooling channels radially outward of the at least one de-congealing inlet channel and the at least one de-congealing outlet channel; and 
 positioning the plurality of cooling channels radially inward of the plurality of cooling fins. 
 
     
     
         15 . A gas turbine engine assembly comprising:
 a core gas turbine engine having an axis of rotation;   a fan casing substantially circumscribing said core gas turbine engine; and   a heat exchanger assembly positioned within said fan casing, said heat exchanger assembly comprising:
 a bypass valve; and 
 at least one body portion including:
 at least one de-congealing inlet channel in flow communication with said bypass valve; 
 a plurality of cooling channels in flow communication with said bypass valve and said at least one de-congealing inlet channel, wherein said bypass valve is configured to deliver a fluid between said at least one de-congealing inlet channel and said plurality of cooling channels during a first mode of operation to facilitate reducing a temperature of the fluid; and 
 at least one de-congealing outlet channel in flow communication with said bypass valve and said at least one de-congealing inlet channel, wherein said bypass valve is configured to deliver the fluid between said at least one de-congealing inlet channel and said at least one de-congealing outlet channel during a second mode of operation. 
 
   
     
     
         16 . The gas turbine engine assembly in accordance with  claim 15  further comprising a plurality of cooling fins extending radially from at least one radially exterior surface of said body portion and configured to receive a flow of air to facilitate reducing a temperature of the fluid flowing through said plurality of cooling channels during the first mode of operation. 
     
     
         17 . The gas turbine engine assembly in accordance with  claim 16 , wherein said heat exchanger assembly is coupled within a recess in said fan casing such that said at least one radially exterior surface is flush with a radially interior surface of said fan casing such that only said plurality of cooling fins are exposed to the flow of air. 
     
     
         18 . The gas turbine engine assembly in accordance with  claim 16 , wherein said plurality of cooling channels are positioned radially outward of said at least one de-congealing inlet channel and said at least one de-congealing outlet channel and are positioned radially inward of said plurality of cooling fins. 
     
     
         19 . The gas turbine engine assembly in accordance with  claim 15 , wherein said bypass valve is configured to deliver the fluid to said at least one de-congealing outlet channel when the fluid reaches a pre-determined temperature. 
     
     
         20 . The gas turbine engine assembly in accordance with  claim 15 , wherein said at least one de-congealing outlet channel is proximate to said plurality of cooling channels such that fluid flow through said at least one de-congealing outlet channel during the second mode of operation facilitates de-congealing an amount of fluid within said plurality of cooling channels.