IP Library › Granted Patent US 12,434,832
Granted Patent B2
US 12,434,832 · App. 18/956,397 · Granted Oct 7, 2025

Systems and methods for lifter motor cooling in evtol aircraft

Inventors: Karthik Kumar Bodla (Houston, TX); Bharat Tulsyan (San Jose, CA); Christopher M. Heath (Avon, OH); Kerry Manning (Parker, CO); Alan D. Tepe (Fremont, CA)
Assignee: Archer Aviation Inc.
B64C29/0033B64D33/08
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Quick Facts
Patent No.
US 12,434,832
App. No.
18/956,397
Filed
Nov 22, 2024
Granted
Oct 7, 2025
Kind
B2
Art Unit
3647
USPC
244/53R
Abstract

An apparatus for aircraft propulsion includes a propeller and a hybrid-cooled electric engine mounted to a support structure and configured to rotate the propeller. The electric engine is located in an enclosure, with a first heat transfer element thermally coupled to the electric engine via a fluid flow path, partially located outside the enclosure. A second heat transfer element, integral to or thermally coupled to the electric engine, provides air cooling. Both heat transfer elements are housed within the aircraft's support structure. At least one air inlet on the upper side of the support structure receives propeller downwash. A first cooling path directs a portion of the downwash from the air inlet to the first heat transfer element, and a first air outlet exhausts the downwash.

Claims (62)

1. An apparatus for aircraft propulsion, comprising:

a propeller;

an electric engine mounted to a support structure and configured to rotate the propeller, the electric engine being located within an enclosure;

a first heat transfer element that is thermally coupled to the electric engine via a fluid flow path, wherein at least part of the first heat transfer element is located external to the enclosure;

a second heat transfer element that is integral to or thermally coupled to the electric engine for air cooling without a fluid intermediary;

the first heat transfer element and the second heat transfer element being located within the support structure;

at least one air inlet located at an upper side of the support structure, wherein the at least one air inlet is configured to receive downwash from the propeller;

a first enclosed cooling path configured to direct a first portion of the downwash from the at least one air inlet to the first heat transfer element;

a second enclosed cooling path configured to direct a second portion of the downwash from the at least one air inlet to the second heat transfer element; and

a first air outlet configured to exhaust the first portion of the downwash from the first heat transfer element.

2. The apparatus for aircraft propulsion of claim 1 , wherein the first heat transfer element comprises a heat exchanger.

3. The apparatus for aircraft propulsion of claim 1 , wherein:

the electric engine comprises a motor; and

the enclosure comprises a motor enclosure enclosing the motor,

wherein the fluid flow path is configured to circulate a fluid within the motor enclosure.

4. The apparatus for aircraft propulsion of claim 1 , wherein the fluid flow path comprises one of an oil or a coolant.

5. The apparatus for aircraft propulsion of claim 2 , wherein the second heat transfer element comprises air-cooling fins that are integral to or thermally coupled to the electric engine.

6. The apparatus for aircraft propulsion of claim 1 ,

wherein the first air outlet is configured to exhaust the second portion of the downwash from the second heat transfer element.

7. The apparatus for aircraft propulsion of claim 1 , further comprising:

a second air outlet, wherein the second air outlet is configured to exhaust the second portion of the downwash from the second heat transfer element.

8. The apparatus for aircraft propulsion of claim 7 , wherein the second air outlet is located at an upper side of the support structure.

9. The apparatus for aircraft propulsion of claim 8 , wherein the second air outlet is annular to or adjacent to a hub of the electric engine.

10. The apparatus for aircraft propulsion of claim 1 , wherein the second enclosed cooling path is configured to direct the second portion of the downwash from the at least one air inlet, to the second heat transfer element, and then to the first heat transfer element.

11. The apparatus for aircraft propulsion of claim 1 , wherein the first enclosed cooling path is configured to direct the first portion of the downwash from the at least one air inlet to the first heat transfer element and then to the second heat transfer element.

12. The apparatus for aircraft propulsion of claim 3 , wherein:

the enclosure comprises an inverter enclosure enclosing an inverter and a dividing plate between an electric engine enclosure enclosing the electric engine and the inverter enclosure enclosing the inverter, wherein the dividing plate is configured to thermally couple the inverter to the fluid flow path.

13. The apparatus for aircraft propulsion of claim 3 , wherein:

the enclosure comprises a gearbox enclosure enclosing a gearbox,

wherein the fluid flow path is configured to circulate fluid within the gearbox enclosure.

14. The apparatus for aircraft propulsion of claim 1 , wherein the first portion of the downwash does not reach the second heat transfer element.

15. The apparatus for aircraft propulsion of claim 1 , wherein the first enclosed cooling path and the second enclosed cooling path are configured to receive downwash from same air inlet.

16. An apparatus for aircraft propulsion, comprising:

a propeller;

an electric engine mounted to a support structure having a longitudinal axis through the center of the support structure, wherein the electric engine is configured to rotate a propeller, the electric engine being located within an enclosure;

a first heat transfer element that is thermally coupled to the electric engine, wherein at least part of the first heat transfer element is located external to the enclosure;

a first air inlet located at an upper side of the support structure, wherein the first air inlet is configured to receive downwash from the propeller during a lift phase, and wherein the first air inlet is radially offset from a hub of the electric engine and the first air inlet is laterally offset from the longitudinal axis, wherein an amount of the lateral offset positions the first air inlet in a region of high downwash pressure or airflow;

a first cooling path configured to direct a first portion of the downwash from the first air inlet to the first heat transfer element; and

a first air outlet configured to exhaust the first portion of the downwash from the first heat transfer element.

17. The apparatus for aircraft propulsion of claim 16 , wherein the first heat transfer element comprises a heat exchanger.

18. The apparatus for aircraft propulsion of claim 17 , further comprising:

a fluid flow path, wherein the heat exchanger is thermally coupled to the electric engine by the fluid flow path.

19. The apparatus for aircraft propulsion of claim 18 , wherein the fluid flow path comprises one of an oil or a coolant.

20. The apparatus for aircraft propulsion of claim 18 , wherein: the electric engine further comprises an inverter; and

the enclosure comprises an inverter enclosure enclosing the inverter and a dividing plate between an electric engine enclosure enclosing the electric engine and the inverter enclosure, wherein the dividing plate is configured to thermally couple the inverter to the fluid flow path.

21. The apparatus for aircraft propulsion of claim 18 , wherein: the electric engine comprises a gearbox; and

the enclosure comprises a gearbox enclosure enclosing the gearbox,

wherein the fluid flow path is configured to circulate fluid within the gearbox enclosure.

22. The apparatus for aircraft propulsion of claim 16 , further comprising:

a second heat transfer element that is thermally coupled to the electric engine, wherein at least part of the second heat transfer element is located external to the enclosure; and

a second cooling path configured to direct a second portion of the downwash from the first air inlet to the second heat transfer element.

23. The apparatus for aircraft propulsion of claim 22 , further comprising:

a second air outlet, wherein the second air outlet is configured to exhaust the second portion of the downwash from the second heat transfer element.

24. The apparatus for aircraft propulsion of claim 23 , wherein the second air outlet is located at an upper side of the support structure.

25. The apparatus for aircraft propulsion of claim 24 , wherein the second air outlet is annular to or adjacent to a hub of the electric engine.

26. The apparatus for aircraft propulsion of claim 22 , wherein the second heat transfer element comprises air-cooling fins integral to or thermally coupled to a part of the electric engine.

27. The apparatus for aircraft propulsion of claim 16 , wherein the amount of lateral offset is based on a swirl component of the downwash.

28. The apparatus for aircraft propulsion of claim 16 , further comprising a second air inlet configured to receive a second portion of the downwash and cool the electric engine,

wherein the second air inlet is laterally offset from the longitudinal axis in a direction opposite from the lateral offset of the first air inlet,

wherein an amount of the lateral offset of the second air inlet positions the second air inlet in a second region of high downwash pressure or airflow.

29. The apparatus for aircraft propulsion of claim 28 , wherein a second cooling path is configured to direct the second portion of the downwash from the second air inlet to the first heat transfer element.

30. The apparatus for aircraft propulsion of claim 28 , wherein the second air inlet is offset from the first air inlet in a longitudinal direction.

Assignments (2)
CORRECTIVE ASSIGNMENT TO CORRECT THE NAME OF ASSIGNEE ARCHER AVIATION INC. PREVIOUSLY RECORDED ON REEL 69376 FRAME 495. ASSIGNOR(S) HEREBY CONFIRMS THE ASSIGNMENT.. Recorded Mar 23, 2026
From: BODLA, KARTHIK KUMAR; TULSYAN, BHARAT; HEATH, CHRISTOPHER M.; MANNING, KERRY; TEPE, ALAN D.
To: ARCHER AVIATION INC.
Reel/Frame 075206/0713 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Nov 22, 2024
From: BODLA, KARTHIK KUMAR; TULSYAN, BHARAT; HEATH, CHRISTOPHER M.; MANNING, KERRY; TEPE, ALAN D.
To: ARCHER AVIATION INC.
Reel/Frame 069376/0495 →
Continuity (4)
Continuation 18163372 · Feb 2, 2023
Continuation 18055268 · Nov 14, 2022
Provisional Application 63378680 · Oct 7, 2022
Related Publication 20250083807A1 · Mar 13, 2025
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