System for thermal gradient reduction of rotor components

Abstract

The present invention relates to a system for reducing thermal gradients in a rotor assembly. Aspects of the present disclosure are directed to a system for reducing thermal gradients at a heat engine. The heat engine includes a rotor assembly having a rotor disk, and a seal assembly is provided. A docking structure at least partially surrounds the rotor assembly at the seal assembly. The seal assembly and the docking structure together form a first cavity defining a first environmental condition and a second cavity defining a second environmental condition. A fluid supply manifold is connected to the rotor assembly and extends at least partially in a radial direction from the first cavity to an outlet opening in thermal communication with the rotor disk of the rotor assembly.

Description

Technical Field

[0001] The present subject matter generally relates to methods and structures for reducing thermal gradients at a rotor assembly for a turbine engine. Background Art

[0002] Rotor assemblies (such as those used in gas turbine engines or, in particular, propulsion systems) generate and receive large temperatures due to the operation of the rotor assembly. These temperatures generally vary along the axial and radial distances of the rotor assembly, such as across multiple stages of the rotor assembly. Such temperature differences across these distances may cause thermal gradients that may reduce the durability or life of the rotor assembly (such as at a specific rotor stage that is exposed to a higher temperature than other rotor stages). Rotor stages exposed to greater temperatures (such as rotor stages closer to the combustion section) and associated higher temperatures may experience greater thermal gradients. As such, known rotor assemblies may be limited by higher pressure ratios, higher temperatures, greater rotor speeds, or necessary durability or life requirements for certain equipment (e.g., equipment associated with a propulsion system).

[0003] For at least these reasons, a need exists for methods and systems for reducing thermal gradients at a rotor assembly. Summary of the invention

[0004] Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.

[0005] Aspects of the present disclosure are directed to a system for reducing thermal gradients at a heat engine. The heat engine includes a rotor assembly having a rotor disk, and a seal assembly is provided. A docking structure at least partially surrounds the rotor assembly at the seal assembly. The seal assembly and the docking structure together form a first cavity defining a first environmental condition and a second cavity defining a second environmental condition. A fluid supply manifold is connected to the rotor assembly and extends at least partially in a radial direction from the first cavity to an outlet opening in thermal communication with the rotor disk of the rotor assembly.

[0006] Technical Solution 1. A thermal engine, the engine comprising:

[0007] a rotor assembly including a rotor disk and a seal assembly;

[0008] a docking structure at least partially surrounding the rotor assembly at the seal assembly, wherein the seal assembly and the docking structure together form a first cavity defining a first environmental condition and a second cavity defining a second environmental condition; and

[0009] A fluid supply manifold is connected to the rotor assembly and extends at least partially in a radial direction from the first cavity to an outlet opening in thermal communication with the rotor disk of the rotor assembly.

[0010] Technical Solution 2. The heat engine according to any of the foregoing technical solutions is characterized in that the fluid supply manifold includes a first manifold portion extending along the radial direction, and wherein the fluid supply manifold includes a second manifold portion extending along the axial direction.

[0011] Technical Solution 3. A heat engine according to any of the foregoing technical solutions, characterized in that the fluid supply manifold includes a third manifold portion extending along the radial direction, wherein the third manifold portion includes the outlet opening that is in fluid communication with the rotor disk of the rotor assembly.

[0012] Technical Solution 4. A heat engine according to any of the preceding technical solutions, characterized in that the first manifold portion comprises an inlet opening in fluid communication with the first chamber.

[0013] Technical Solution 5. The heat engine according to any of the above technical solutions is characterized in that the third manifold portion is positioned on the inner side of the rotor disk along the radial direction.

[0014] Technical Solution 6. The heat engine according to any of the above technical solutions is characterized in that the third manifold portion forms an airfoil.

[0015] Technical Solution 7. The heat engine according to any of the preceding technical solutions is characterized in that the fluid supply manifold comprises a plurality of the third manifold portions arranged in a circumferential arrangement relative to each other.

[0016] Technical Solution 8. The heat engine according to any of the preceding technical solutions, characterized in that the fluid supply manifold comprises a plurality of the first manifold portions arranged in a circumferential arrangement relative to each other.

[0017] Technical Solution 9. The heat engine according to any of the preceding technical solutions is characterized in that fluid passages are formed between adjacent pairs of the plurality of first manifold portions arranged in a circumferential arrangement.

[0018] Technical Solution 10. A thermal engine according to any of the foregoing technical solutions, characterized in that the engine forms a first chamber adjacent to a first side of the rotor disk, a second chamber adjacent to a second side of the rotor disk opposite to the first side of the rotor disk, wherein the second chamber is formed between the rotor disk and the sealing assembly, and wherein the engine forms a third chamber adjacent to the sealing assembly opposite to the second chamber.

[0019] Technical Solution 11. The heat engine according to any of the preceding technical solutions, characterized in that the fluid supply manifold comprises a fluid exhaust manifold positioned between the first chamber and the second chamber, wherein the outlet opening is positioned at the fluid exhaust manifold.

[0020] Technical Solution 12. A heat engine according to any of the preceding technical solutions, characterized in that a fluid passage is formed between adjacent pairs of a plurality of first manifold portions arranged in a circumferential arrangement, wherein the fluid passage provides fluid communication between the second chamber and the third chamber.

[0021] Technical Solution 13. A thermal engine according to any of the foregoing technical solutions, characterized in that the fluid supply manifold including the plurality of first manifold portions forms a fluid flow path from the first chamber to the outlet opening, and wherein the fluid supply manifold separates the fluid flow path from the second chamber and the third chamber fluids.

[0022] Technical Solution 14. A heat engine according to any of the preceding technical solutions, characterized in that the outlet opening is positioned in a fluid impingement relationship with the rotor disk.

[0023] Technical Solution 15. The heat engine according to any of the preceding technical solutions, characterized in that the sealing assembly includes a compressor discharge pressure seal positioned between the compressor section and the turbine section.

[0024] Technical Solution 16. The heat engine according to any of the foregoing technical solutions is characterized in that the rotor disk is positioned at the compressor section.

[0025] Technical Solution 17. A heat engine according to any of the preceding technical solutions, characterized in that the rotor assembly comprises a shaft extending to the compressor section and the turbine section, and wherein the fluid supply manifold is coupled to the shaft.

[0026] Technical Solution 18. A thermal engine according to any of the foregoing technical solutions, characterized in that the fluid supply manifold includes a first manifold portion extending along the radial direction, and wherein the fluid supply manifold includes a second manifold portion extending along an axial direction that is the same as the axis, and wherein the fluid supply manifold includes a third manifold portion extending along the radial direction on the inner side of the rotor disk, wherein the third manifold portion includes the outlet opening connected to the rotor disk fluid of the rotor assembly.

[0027] Technical Solution 19. The heat engine according to any of the preceding technical solutions, characterized in that the first cavity is positioned distally of the compressor section, and wherein the second cavity is positioned proximally of the compressor section relative to the first cavity.

[0028] Technical Solution 20. A thermal engine according to any of the foregoing technical solutions, characterized in that a fluid passage is formed between adjacent pairs of a plurality of the first manifold parts arranged in a circumferential arrangement, and the fluid supply manifold including the plurality of the first manifold parts forms a fluid flow path from the first chamber to the outlet opening, and wherein the fluid supply manifold separates the fluid flow path from the third chamber fluid adjacent to the sealing assembly opposite to the second chamber.

[0029] These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims.The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the present invention and, together with the description, serve to explain the principles of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] A complete and enabling disclosure of the present invention, including the best mode thereof, to one of ordinary skill in the art is set forth in the specification with reference to the accompanying drawings, in which:

[0031] Figure 1 is a schematic cross-sectional view of a turbomachine including a system for reducing thermal gradients at a rotor assembly according to aspects of the present disclosure;

[0032] Figure 2 is a perspective view of an exemplary embodiment of a system for reducing thermal gradients at a rotor assembly according to aspects of the present disclosure;

[0033] Figure 3 for Figure 2 A close-up view of the system;

[0034] Figure 4 for Figure 2-3 A schematic cross-sectional view of an embodiment of a system of; and

[0035] Figure 5 for Figure 2-4 Schematic cross-sectional view of an embodiment of a system.

[0036] Repeat use of reference characters in the present specification and drawings is intended to represent same or analogous features or elements of the invention. DETAILED DESCRIPTION

[0037] Reference will now be made in detail to embodiments of the present invention, one or more examples of which are illustrated in the accompanying drawings. Each example is provided by way of explanation of the present invention rather than by way of limitation of the present invention. In fact, it will be apparent to those skilled in the art that various modifications and variations may be made in the present invention without departing from the scope or spirit of the present invention. For example, a feature illustrated or described as part of an embodiment may be used together with another embodiment to produce other additional embodiments. Therefore, it is intended that the present invention encompasses such modifications and variations as fall within the scope of the appended claims and their equivalents.

[0038] As used herein, the terms “first,” “second,” and “third” may be used interchangeably to distinguish one component from another, and are not intended to indicate the position or importance of individual components.

[0039] The terms "upstream" and "downstream" refer to relative directions with respect to fluid flow in a fluid pathway. For example, "upstream" refers to the direction from which the fluid flows, and "downstream" refers to the direction to which the fluid flows.

[0040] A system for reducing the gradient of a rotor assembly is provided. The system depicted and described herein includes a fluid supply manifold connected to the rotor assembly and extending to an outlet opening that is thermally connected to a rotor disk of the rotor assembly so as to reduce the thermal gradient at the rotor assembly. As the compressor section extends from the front inlet to the rear outlet (e.g., the compressor outlet or the combustor section inlet station) typically associated with the station 3 of the gas turbine engine, the temperature at the front end varies significantly from the front end to the rear end, which can cause a thermal gradient that can reduce the durability or life of the rotor assembly. In addition, the radially inner portion of the rotor assembly is typically cooler than the radially outer portion at or near the gas flow path, where the oxidant is compressed and the temperature increases. The system provided herein allows the fluid to impinge on the desired rotor disk (such as a rotor disk opening) to reduce the thermal gradient. In certain embodiments provided herein, a relatively warm fluid (e.g., at or near the station 3) is directed to the radially inner portion of the rotor assembly (such as a rotor disk opening) to reduce the thermal gradient. The reduction in thermal gradient allows for improved rotor durability and improved cycle fatigue. The systems provided herein may further allow for more advantageous positioning of the fluid drain to improve specific fuel consumption (SFC).

[0041] Reference now Figure 1, a schematic cross-sectional view of a turbine engine 10 (hereinafter, "engine 10") including a system for reducing thermal gradients at a rotor assembly 90 according to aspects of the present disclosure is provided. The engine 10 may generally define any system including a rotor assembly 90 that is configured to pressurize an oxidant flow 63 passing through the rotor assembly 90 across one or more stages. In certain embodiments, the engine 10 may be configured as a propulsion system, such as a turbofan engine, a turboprop engine, a turbojet engine, a propfan engine, an open rotor, or an unducted fan engine. In other embodiments, the engine 10 may be configured as a power generation system, such as an industrial gas turbine engine, a marine gas turbine engine, or an auxiliary power unit.

[0042] The engine 10 defines a centerline axis 12 extending along an axial direction A. A radial direction R extends from the centerline axis 12. A circumferential direction extends relative to the centerline axis 12. An exemplary embodiment of the engine 10 provided herein includes a compressor section 21, a combustion section 26, and a turbine section 27 positioned in a serial flow arrangement. In certain embodiments, the engine 10 includes a first compressor 22 coupled to a first turbine 28 by a first shaft 34. In one embodiment, the first compressor 22, the first turbine 28, and the first shaft 34 together define a high-speed rotating shaft. In certain other embodiments, the engine 10 includes a second compressor 24 coupled to a second turbine 30 by a second shaft 35. In one embodiment, the second compressor 24, the second turbine 30, and the second shaft 35 together define a low-speed rotating shaft relative to the high-speed rotating shaft. The high-speed rotating shaft and the low-speed rotating shaft are generally configured in a mechanically rotatable independent arrangement (except for the aerodynamic effect of the serial air flow therethrough).

[0043] In various embodiments, the engine 10 includes a propeller or fan assembly 14 positioned in a serial flow arrangement with a low speed rotor shaft. Figure 1 In one embodiment depicted in FIG. 1 , the fan assembly 14 is positioned forward of the compressor section 21 . However, it should be appreciated that other embodiments of the engine 10 may include a fan assembly 14 positioned aft of the turbine section 27 .

[0044] In such Figure 1, the engine 10 includes a gear assembly 44 configured in a mechanically operable arrangement between the fan assembly 14 and the second turbine 30 of the turbine section 27. The gear assembly 44 may allow the engine 10 to be configured as an indirectly driven engine, thereby allowing different rotational speeds of the fan assembly 14 relative to the second turbine 30. In one embodiment, the fan assembly 14 includes a fan shaft 36 connected to the gear assembly 44 and configured to receive power and torque from the second turbine 30. However, it should be appreciated that other embodiments of the engine 10 may define a direct drive engine without a gear assembly, where the fan assembly and the second turbine rotate at substantially similar rotational speeds.

[0045] The engine 10 generally includes a plurality of bearing assemblies 88 including a housing, frame or other fixed structure, bearings (e.g., roller bearings, tapered roller bearings, ball or thrust bearings, fluid bearings, journal bearings or other suitable bearing assemblies), and a fluid manifold configured to supply a fluid, including but not limited to a lubricant, a damping fluid, or a cooling fluid, to and from the bearing assemblies 88. The bearing assemblies 88 are generally configured to support rotation of a rotor assembly 90 and receive thrust or torque.

[0046] The rotor assembly 90 as depicted and described herein may include all or part of a high speed shaft or a low speed shaft such as defined herein. The engine 10 further includes a static structure 89 surrounding the rotor assembly 90, such as further described herein. In various embodiments, the static structure 89 includes the combustion section casing 25. In other embodiments, the static structure 89 includes at least a portion of a bearing assembly 88, such as further described herein.

[0047] Reference now Figure 2-5 , perspective and cross-sectional views of a system for supplying a thermal fluid to a rotor assembly (hereinafter, "system 100") are provided. In various embodiments, system 100 is positioned with respect to a heat engine (such as with respect to Figure 1 The system 100 is in fluid communication with a rotor assembly 90 of the engine 10 depicted and described. However, it should be appreciated that the system 100 may be generally applied at the rotor assembly to direct fluid to the rotor disks to reduce thermal gradients at the rotor disks.

[0048] refer to Figure 2-5 The system 100 includes a fluid supply manifold 110 ( Figure 3). As noted above, rotor assembly 90 includes rotor disk 91, which generally defines a bladed disk, hub, aperture, integral bladed rotor, or other suitable structure for carrying an airfoil assembly for a turbine. Rotor assembly 90 further includes a seal assembly disk 92, at which a seal assembly 93 is defined. Seal assembly 93 is positioned in an operative arrangement with a docking structure to form a first cavity 111 defining a first environmental condition and a second cavity 112 defining a second environmental condition, the second environmental condition being different from the first environmental condition. The environmental conditions may include one or more of the following: pressure, temperature, density, viscosity, or other physical parameter of a fluid at least partially contained in the respective first cavity 111 and second cavity 112.

[0049] It should be appreciated that the docking structure is any structure where the first cavity 111 and the second cavity 112 are at least partially formed based on the rotor assembly 90, the seal assembly disk 92 including the seal assembly 93, and the docking structure. Figure 2 In one embodiment depicted in FIG. 1 , the docking structure may be the combustion section 26. In a particular embodiment, the docking structure is the inner casing of the combustion section 26. However, it should be appreciated that the docking structure may be a generally static structure, such that the seal assembly 93 is a static-rotating structure interface. Further, it should be appreciated that the docking structure may be a rotating structure, such that the seal assembly 93 is a rotating-rotating structure interface, such as, for example, a co-rotating or counter-rotating rotor assembly, or an interdigitated rotor structure.

[0050] In various embodiments, the sealing assembly 93 forms a labyrinth seal with the docking structure. In other various embodiments, the sealing assembly 93 includes a face seal. In other various embodiments, the sealing assembly 93 includes a carbon seal. In one or more embodiments, the sealing assembly 93 extends along the axial direction A and the circumference. Based on the desired or expected pressure, temperature, flow rate, rotor speed or other operating conditions for the rotor assembly 90, various diameters and / or lengths associated with the sealing assembly 93 may be applied to provide appropriate clearance, pressure drop, leakage, etc.

[0051] Return to reference Figure 2-5 , the fluid supply manifold 110 extends along the radial direction R. In one embodiment, the fluid supply manifold 110 extends in the same direction as at least the sealing assembly disk 92. Figure 3-4) is formed at least at the fluid supply manifold 110 to provide fluid communication from the first cavity 111 to the outlet opening 122, which is in thermal communication with the rotor disk 91. It should be appreciated that in certain embodiments, the inlet opening 121 may be at least partially formed through the rotor assembly 90 to provide fluid communication from the first cavity 111 to the outlet opening 122. In various embodiments, the outlet opening 122 is positioned in fluid impingement relationship with the rotor disk 91 so that the fluid flow from the first cavity 111 (schematically depicted via arrow 131) is released to the rotor disk 91 (schematically depicted via arrow 133) to desirably affect the thermal gradient at the rotor disk 91.

[0052] In various embodiments, the fluid supply manifold 110 includes a first manifold portion 101 extending along a radial direction R. For example, the first manifold portion 101 can extend substantially co-directionally with or adjacent to the seal assembly disk 92 along the radial direction R. The first manifold portion 101 at least partially forms a fluid flow path 105 from the first cavity 111 to the outlet opening 122.

[0053] The fluid supply manifold 110 further includes a second manifold portion 102 extending along an axial direction A. For example, the second manifold portion 102 may extend generally co-directionally or adjacent to the axis 94 of the rotor assembly 90. In certain embodiments, the fluid flow path 105 extends from the first cavity 111 along a radial direction R (such as co-directionally with the seal assembly disk 92) and along an axial direction A (such as co-directionally with the axis 94). In certain embodiments, the second manifold portion 102 includes a generally circumferential hollow chamber configured as a collector to circumferentially normalize pressure and / or temperature for a fluid flow 131 (such as depicted via arrows 132) from the first manifold portion 101 through the second manifold portion 102. In other embodiments, all or part of the second manifold portion 102 may define a separate hollow chamber that corresponds at least partially to one or more of the first manifold portions 101.

[0054] In certain embodiments, the fluid supply manifold 110 includes a fluid discharge manifold or third manifold portion 103 extending along a radial direction R. The third manifold portion 103 includes an outlet opening 122 in fluid communication with the rotor disk 91. In various embodiments, the third manifold portion 103 is positioned in certain desirable relationships with the rotor disk 91 so as to reduce thermal gradients at the rotor disk 91 via the release of fluid supplied from the first cavity 111 to the rotor disk 91 via the outlet opening 122. In one embodiment, at least a portion of the third manifold portion 103 is positioned inboard of the rotor disk 91 along the radial direction R. The outlet opening 122 may be correspondingly positioned inboard of the rotor disk 91 and oriented to release the fluid flow 133 onto the rotor disk 91. In other embodiments, the third manifold portion 103 may at least partially surround the rotor disk 91 along the axial direction A and / or the radial direction R. Correspondingly, the outlet opening 122 may be positioned axially alongside the rotor disk 91.

[0055] refer to Figure 2-3 In certain embodiments, the fluid supply manifold 110 includes a plurality of third manifold portions 103 arranged in a circumferential arrangement relative to each other. The plurality of third manifold portions 103 positioned in a spaced-apart circumferential arrangement allow fluid communication from a first side 191 of the third manifold 103 to a second side 291 opposite the first side 191, such as further described herein.

[0056] In other specific embodiments, the fluid supply manifold 110 includes a plurality of first manifold portions 101 arranged in a circumferential arrangement relative to each other. The plurality of first manifold portions 101 may form a plurality of discrete first manifold portions 101 spaced apart from each other. The plurality of first manifold portions 101 positioned in a spaced apart circumferential arrangement allow fluid communication from the first side 192 to the second side 292 of the seal assembly disk 92, such as further described herein.

[0057] Reference now Figure 4-5 , the system 100 described herein including the rotor assembly 90 and the fluid supply manifold 110 forms a first plenum 95 adjacent to the rotor disk 91 and the first side 191 of the third manifold 103. The system 100 further forms a second plenum 96 from the second side 291 of the rotor disk 91 to the first side 192 of the seal assembly disk 92, such that the second plenum 96 is formed between the rotor disk 91 and the seal assembly disk 92. The system 100 additionally further forms a third plenum 97 adjacent to the first manifold portion 101 and the second side 292 of the seal assembly disk 92. For example, the third plenum 97 is formed at a side of the seal assembly disk 92 that is generally opposite to the second plenum 96.

[0058] During operation of the engine 10 including the system 100, the first plenum 95, the second plenum 96, and the third plenum 97 form environmental conditions that are at least partially different from each other. During operation, the fluid flow 131 enters the fluid flow path 105 that is fluidly separated from the second plenum 96 and the third plenum 97 by the fluid supply manifold 110 until the fluid flow 131 is discharged in thermal communication with the rotor disk 91 via the outlet opening 122. The operation of the engine 10 forms a fluid flow at the first plenum 95 (schematically depicted via arrows 195). The fluid flow 195 to the first plenum 95 can generally define a thermally cooler fluid relative to the fluid flow 131 from the first cavity 111. In certain embodiments, the fluid flow 195 is compressed air from an upstream stage relative to the fluid flow 131 from the relatively downstream stage or compressor outlet. In various embodiments, the fluid flow 131 is compressor discharge pressure (CDP) air or station 3 flow path air directed into the fluid supply manifold 110. However, it should be appreciated that fluid stream 131 is generally any suitable fluid that defines greater environmental conditions (such as temperature and / or pressure) than fluid streams 195 , 196 .

[0059] In certain embodiments, the fluid flow 131 impinging on the rotor disk 91 reduces the thermal gradient at the rotor disk 91 by warming the radially inner portion of the rotor disk 91. In one embodiment, the third manifold 103 includes a longer length along the axial direction A relative to the rotor disk 91. In certain embodiments, the outlet opening 122 is positioned to provide, release or impinge the fluid flow 133 onto the axially extending inner portion or opening of the rotor disk 91. In another embodiment, the outlet opening 122 is positioned to provide, release or impinge the fluid flow 133 against the radially extending portion of the rotor disk 91. By warming the radially inner portion of the rotor disk 91, the difference in temperature (i.e., thermal gradient) from the inner portion to the radially outer portion of the rotor disk 91 or the airfoil attached thereto is reduced. The reduced thermal gradient at the rotor disk 91 allows for increased cyclic fatigue life, such as by reducing stresses that may be caused by significant temperature differences between the radially inner portion and the radially outer portion of the rotor disk 91.

[0060] Additional or alternative benefits include faster rotor thermal response, such as by allowing the mass of the surrounding casing to be reduced so as to beneficially affect rotor-stator or rotor-casing clearances. As such, improved clearances allow for improved engine operation, operability, and performance.

[0061] During operation of the engine 10 including the system 100, the relatively cooler fluid stream 195 mixes with the relatively warmer fluid stream 133, which is discharged from the outlet opening 122 onto the rotor disk 91. A mixed flow (schematically depicted via arrow 196) is formed in the second plenum 96, which generally defines an environmental condition between the fluid stream 195 and the fluid streams 131, 132, 133. The fluid stream 196 is allowed to flow from the second plenum 96 to the third plenum 97 via a first fluid passage 123 formed between adjacent pairs of the plurality of first manifold portions 101, such as depicted via arrow 197. As such, the fluid passage 123 provides fluid communication between the second plenum 96 and the third plenum 97 to allow the fluid stream 196 to flow out to other portions of the engine 10, for example, to provide cooling, reduce thermal gradients, provide thermal attenuation, etc. In embodiments such as in conjunction with the first manifold portion 101, the fluid stream 195 may be used to provide a plurality of cooling channels, such as a plurality of cooling channels, to reduce thermal gradients, to provide thermal attenuation, etc. Figure 1 In certain depicted embodiments, fluid passage 123 allows fluid communication of fluid 196 from compressor section 21 to turbine section to provide cooling, thermal gradient reduction, or other thermal attenuation at turbine section 27 .

[0062] In certain embodiments, the third manifold portion 103 forms an airfoil. A plurality of third manifold portions 103 may together form a plurality of airfoils, each of which includes a pressure side, a suction side, a leading edge, and a trailing edge. During operation of the engine 10, the rotation of the rotor assembly 90 including the plurality of third manifold portions 103 may accelerate the fluid flow 195, or cause the fluid flow 195 to be ejected from the first plenum 95 to the second plenum 96 via the second fluid passage 124, which is formed between adjacent pairs of the plurality of third manifold portions 103. The third manifold portion 103 forming an airfoil may further accelerate or pressurize the fluid flows 195, 196. The third manifold portion 103 configured to accelerate or pressurize the fluid flows 195, 196 may overcome or offset the potential adverse effects of the fluid supply manifold 110 (relative to allowing the fluid flow 195 to a downstream location for use as, for example, a cooling fluid, reducing thermal gradients, attenuating thermal conditions, etc.).

[0063] Additionally or alternatively, the third manifold portion 103, which is configured to accelerate or pressurize the fluid flows 195, 196, allows the gas flow path 87 ( Figure 1 ) discharges or receives a lesser pressure fluid flow 195. For example, in contrast to known air discharge openings and systems, discharging the lesser pressure fluid flow 195 includes receiving air further upstream in the compressor section 21. In another example, discharging the lesser pressure fluid flow 195 includes receiving air further downstream in the turbine section 27, where the air defines a lesser pressure and / or temperature.

[0064] In certain additional embodiments, the fluid supply manifold 110 is coupled to the seal assembly disk 92. In one embodiment, the fluid supply manifold 110 is coupled to the shaft 94. The fluid supply manifold 110 may be positioned radially between the shaft 94 and the seal assembly disk 92.

[0065] Various embodiments of the engine 10 and system 100 provided herein may define the seal assembly disk 92 as a compressor discharge pressure (CDP) seal positioned between the compressor section 21 and the turbine section 27. In such embodiments, the interface structure includes the combustion section 26.

[0066] Various other embodiments of the engine 10 and system 100 provided herein may define the rotor disk 91 as one or more stages of the compressor section 21. In one embodiment, the rotor disk 91 may define one or more final stages of the compressor section 21. The fluid flow 196 may generally be provided as a cooling fluid or a heat decay fluid to one or more portions of the turbine section 27. In another embodiment, the first cavity 111 is positioned distally of the compressor section 21, and the second cavity 112 is positioned proximally of the compressor section 21 relative to the first cavity 111.

[0067] Still other various embodiments of the engine 10 and system 100 provided herein may define a rotor disk 91 as one or more stages of the compressor section 21, and further define a seal assembly disk 92 between portions of the compressor section 21, or between the fan assembly 14 and the compressor section 21. In one embodiment, the seal assembly disk 92 is positioned between a low-pressure or intermediate-pressure compressor assembly and a high-pressure compressor assembly. In another embodiment, the seal assembly disk 92 is positioned between a bearing assembly and one or more compressors of the compressor section 21.

[0068] Still other embodiments of the engine 10 and system 100 provided herein may define the rotor disk 91 as one or more stages of the turbine section 27, and further define the seal assembly disk 92 between portions of the turbine section 27, or between the turbine section 27 and the compressor section 21. In one embodiment, the seal assembly disk 92 is positioned between the low-pressure or intermediate-pressure turbine assembly and the high-pressure turbine assembly. In another embodiment, the seal assembly disk 92 is positioned between the bearing assembly and one or more turbines of the turbine section 27.

[0069] One or more components of the engine 10 and system 100 described herein may be manufactured or formed using any suitable process, such as an additive manufacturing process, such as a 3D printing process. The use of such a process may allow such components to be integrally formed as a single, unitary component or formed into any suitable number of sub-components. In particular, the additive manufacturing process may allow such components to be integrally formed and include a variety of features that are not possible when using existing manufacturing methods. For example, the additive manufacturing method described herein enables the first manifold portion 101, the second manifold portion 102, the third manifold portion 103, the inlet opening 121, the outlet opening 122, and the fluid flow path 105, or a combination or portion thereof, to be manufactured as an integral, unitary component that may not be possible or practical when using existing manufacturing methods. As another example, the fluid supply manifold 110 may include one or more structures, the one or more structures including airfoils, guide vanes, walls, protrusions, turbulators, or other flow control surfaces formed in the flow path, chamber, or manifold of the fluid supply manifold 110 so as to change the environmental conditions of the fluid flow through the fluid supply manifold 110.

[0070] As used herein, the terms "additive manufacturing" or "additive manufacturing techniques or processes" generally refer to a manufacturing process in which successive layers of (multiple) materials are placed on top of each other to "build up" a three-dimensional component layer by layer. The successive layers are generally fused together to form a monolithic component that may have a variety of integral sub-components. Although additive manufacturing processes are described herein as achieving the production of complex objects by typically building up the object point by point and layer by layer in a vertical direction, other production methods are possible and within the scope of the present subject matter. For example, although the discussion herein relates to adding materials to form successive layers, those skilled in the art will recognize that the methods and structures disclosed herein may be practiced using any additive manufacturing technique or manufacturing process. For example, embodiments of the present invention may use a layer addition process, a layer subtraction process, or a hybrid process.

[0071] Suitable additive manufacturing techniques in accordance with the present disclosure include, for example, fused deposition modeling (FDM), selective laser sintering (SLS), 3D printing (such as by inkjet, laser jetting, and binder jetting), stereolithography (SLA), direct selective laser sintering (DSLS), electron beam sintering (EBS), electron beam melting (EBM), laser engineered net shaping (LENS), laser net shape manufacturing (LNSM), direct metal deposition (DMD), digital light processing (DLP), direct selective laser melting (DSLM), selective laser melting (SLM), direct metal laser melting (DMLM), and other known processes.

[0072] The additive manufacturing process described herein can be used to form components using any suitable material. For example, the material can be plastic, metal, concrete, ceramic, polymer, epoxy resin, photopolymer resin, or any other suitable material (which can be solid, liquid, powder, sheet, wire, or any other suitable form), or a combination thereof. More specifically, according to exemplary embodiments of the present subject matter, the additive manufacturing components described herein can be partially, entirely formed by the following materials or formed with a certain combination of the following materials: the material includes but is not limited to pure metals, nickel alloys, chromium alloys, titanium, titanium alloys, magnesium, magnesium alloys, aluminum, aluminum alloys, and nickel or cobalt-based superalloys (e.g., nickel or cobalt-based superalloys that can be obtained under the name Inconel®, which can be obtained from Special Metals Corporation). These materials are examples of materials suitable for use in the additive manufacturing process described herein, and can be generally referred to as "additive materials".

[0073] In addition, the additive manufacturing process disclosed herein allows a single component to be formed by a variety of materials. Therefore, the components described herein can be formed by any suitable mixture of the above-mentioned materials. For example, the component may include multiple layers, segments or parts, which are formed using different materials, processes and / or formed on different additive manufacturing machines. In this way, the following components can be constructed: the component has different materials and material properties to meet the needs of any specific application. In addition, although the components described herein are constructed entirely by additive manufacturing processes, it should be appreciated that in alternative embodiments, all or part of these components can be formed via casting, machining and / or any other suitable manufacturing process. In fact, any suitable combination of materials and manufacturing methods can be used to form these components.

[0074] Notably, in exemplary embodiments, several features of the components described herein were not previously possible due to manufacturing constraints. However, the inventors have advantageously utilized current advances in additive manufacturing technology to develop exemplary embodiments of such components generally in accordance with the present disclosure. While the present disclosure is generally not limited to the use of additive manufacturing to form these components, additive manufacturing does provide a variety of manufacturing advantages, including ease of manufacturing, reduced cost, greater accuracy, etc.

[0075] In this regard, even multi-part components can be formed as a single continuous piece of metal using additive manufacturing methods, and can therefore include fewer sub-components and / or joints than existing designs. The integrated formation of these multi-part components by additive manufacturing can advantageously improve the overall assembly process. For example, the integrated formation reduces the number of separate parts that must be assembled, thereby reducing the associated time and overall assembly costs. In addition, existing issues regarding, for example, leakage, joint quality between separate parts, and overall performance can be advantageously reduced.

[0076] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems, and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that are not different from the literal language of the claims, or if they include equivalent structural elements that are not substantially different from the literal language of the claims.

[0077] Further aspects of the invention are provided by the subject matter of the following clauses:

[0078] 1. A heat engine, the engine comprising a rotor assembly, the rotor assembly comprising a rotor disk and a seal assembly. The engine further comprises a docking structure at least partially surrounding the rotor assembly at the seal assembly, wherein the seal assembly and the docking structure together form a first cavity defining a first environmental condition and a second cavity defining a second environmental condition. A fluid supply manifold is connected to the rotor assembly and extends at least partially in a radial direction from the first cavity to an outlet opening in thermal communication with a rotor disk of the rotor assembly.

[0079] 2. A heat engine according to any one or more of the clauses herein, wherein the fluid supply manifold comprises a first manifold portion extending along a radial direction, and wherein the fluid supply manifold comprises a second manifold portion extending along an axial direction.

[0080] 3. A heat engine according to any one or more of the clauses herein, wherein the fluid supply manifold comprises a third manifold portion extending in a radial direction, wherein the third manifold portion forms an outlet opening in fluid communication with a rotor disk of the rotor assembly.

[0081] 4. A heat engine according to any one or more of the clauses herein, wherein the first manifold portion forms an inlet opening in fluid communication with the first chamber.

[0082] 5. A heat engine according to any one or more of the clauses herein, wherein the third manifold portion is positioned inside the rotor disk in a radial direction.

[0083] 6. A heat engine according to any one or more of the clauses herein, wherein the third manifold portion forms an airfoil.

[0084] 7. A heat engine according to any one or more of the clauses herein, wherein the fluid supply manifold comprises a plurality of third manifold portions arranged in a circumferential arrangement relative to each other.

[0085] 8. A heat engine according to any one or more of the clauses herein, wherein the fluid supply manifold comprises a plurality of first manifold portions arranged in a circumferential arrangement relative to each other.

[0086] 9. A heat engine according to any one or more of the clauses herein, wherein fluid passages are formed between adjacent pairs of the plurality of first manifold portions arranged in a circumferential arrangement.

[0087] 10. The heat engine of claim 1 , wherein the engine forms a first chamber adjacent to a first side of the rotor disk, a second chamber adjacent to a second side of the rotor disk opposite the first side of the rotor disk, wherein the second chamber is formed between the rotor disk and the seal assembly, and wherein the engine forms a third chamber adjacent to the seal assembly opposite the second chamber.

[0088] 11. A heat engine according to any one or more of the clauses herein, wherein the fluid supply manifold comprises a fluid exhaust manifold positioned between the first plenum and the second plenum, wherein the outlet opening is positioned at the fluid exhaust manifold.

[0089] 12. A heat engine according to any one or more of the clauses herein, wherein a fluid passage is formed between adjacent pairs of the plurality of first manifold portions arranged in a circumferential arrangement, wherein the fluid passage provides fluid communication between the second chamber and the third chamber.

[0090] 13. A heat engine according to any one or more of the clauses herein, wherein a fluid supply manifold comprising a plurality of first manifold portions forms a fluid flow path from the first chamber to the outlet opening, and wherein the fluid supply manifold fluidically separates the fluid flow path from the second chamber and the third chamber.

[0091] 14. A heat engine according to any one or more of the clauses herein, wherein the outlet opening is positioned in fluid impingement relationship with the rotor disk.

[0092] 15. A heat engine according to any one or more of the clauses herein, wherein the seal assembly comprises a compressor discharge pressure seal positioned between the compressor section and the turbine section.

[0093] 16. A heat engine according to any one or more of the clauses herein, wherein the rotor disks are positioned at the compressor section.

[0094] 17. A heat engine according to any one or more of the clauses herein, wherein the rotor assembly comprises a shaft extending to the compressor section and the turbine section, and wherein the fluid supply manifold is coupled to the shaft.

[0095] 18. A heat engine according to any one or more of the clauses herein, wherein the fluid supply manifold comprises a first manifold portion extending in a radial direction, and wherein the fluid supply manifold comprises a second manifold portion extending in an axial direction co-directional with the shaft, and wherein the fluid supply manifold comprises a third manifold portion extending in a radial direction on the inner side of the rotor disk, wherein the third manifold portion comprises an outlet opening in fluid communication with the rotor disk of the rotor assembly.

[0096] 19. A heat engine according to any one or more of the clauses herein, wherein the first cavity is positioned distally of the compressor section, and wherein the second cavity is positioned proximally of the compressor section relative to the first cavity.

[0097] 20. A heat engine according to any one or more of the clauses herein, wherein a fluid passage is formed between adjacent pairs of a plurality of first manifold portions arranged in a circumferential arrangement, and wherein a fluid supply manifold including the plurality of first manifold portions forms a fluid flow path from a first chamber to an outlet opening, and wherein the fluid supply manifold fluidically isolates the fluid flow path from a third chamber adjacent to the seal assembly opposite the second chamber.

[0098] 21. A turbomachine engine comprising a heat engine according to any one or more of the clauses herein.

[0099] 22. A method for reducing thermal gradients in a rotor assembly, the method comprising flowing a first fluid from a first cavity and causing the first fluid to flow out to impinge on a rotor disk, and mixing the outflowing first fluid with a relatively cooler second fluid, and mixing the first fluid with the second fluid.

[0100] 23. A method according to any one or more of the clauses herein, comprising flowing the mixture of the first fluid and the second fluid to a downstream structure.

[0101] 24. A method according to any one or more of the clauses herein, wherein the downstream structure is downstream relative to the compressor section.

[0102] 25. A method according to any one or more of the clauses herein, wherein the downstream structure is a subsequent stage of a compressor section, a combustion section or a turbine section.

[0103] 26. A method according to any one or more of the clauses herein, wherein flowing the mixture of the first fluid and the second fluid to a downstream structure comprises flowing the mixture through a plurality of circumferentially arranged airfoils to accelerate the fluid flow downstream.

[0104] 27. A turbomachine configured to perform the steps of the method according to any one or more of the clauses herein.

[0105] 28. A propulsion system configured to perform the steps of the method according to any one or more of the clauses herein.

[0106] 29. A propulsion system comprising a heat engine according to any one or more of the clauses herein.

Claims

1. A thermal engine, comprising: compressor section; a turbine section positioned rearwardly of the compressor section; a rotor assembly including a rotor disk and a seal assembly; a docking structure at least partially surrounding the rotor assembly at the seal assembly, wherein the seal assembly and the docking structure together form a first cavity defining a first environmental condition and a second cavity defining a second environmental condition; as well as a fluid supply manifold connected to the rotor assembly, the fluid supply manifold comprising an inlet opening at the first cavity and an outlet opening at the rotor disk, wherein the inlet opening is positioned rearward of the seal assembly, wherein the fluid supply manifold extends at least partially in a radial direction from the inlet opening at the first cavity to the outlet opening at the rotor disk, and Wherein rearward is defined as a downstream direction relative to gas flow through the compressor section and the turbine section.

2. The heat engine according to claim 1, characterized in that The fluid supply manifold comprises a first manifold portion extending along the radial direction, and wherein the fluid supply manifold comprises a second manifold portion extending along an axial direction.

3. The heat engine according to claim 2, characterized in that The fluid supply manifold includes a third manifold portion extending along the radial direction, wherein the third manifold portion includes the outlet opening in fluid communication with the rotor disk of the rotor assembly.

4. The heat engine according to claim 3, characterized in that The first manifold portion includes the inlet opening in fluid communication with the first chamber.

5. The heat engine according to claim 3, characterized in that: The third manifold portion is positioned inside the rotor disk along the radial direction.

6. The heat engine according to claim 3, characterized in that The third manifold portion forms an airfoil.

7. The heat engine according to claim 3, characterized in that The fluid supply manifold comprises a plurality of the third manifold portions arranged in a circumferential arrangement relative to each other.

8. The heat engine according to claim 2, characterized in that The fluid supply manifold includes a plurality of the first manifold portions arranged in a circumferential arrangement relative to one another.

9. The heat engine according to claim 8, characterized in that Fluid passages are formed between adjacent pairs of the plurality of first manifold portions arranged in a circumferential arrangement.

10. The heat engine according to claim 1, characterized in that The engine forms a first chamber adjacent to a first side of the rotor disk, a second chamber adjacent to a second side of the rotor disk opposite the first side of the rotor disk, wherein the second chamber is formed between the rotor disk and the seal assembly, and wherein the engine forms a third chamber adjacent to the seal assembly opposite the second chamber.

11. The heat engine according to claim 10, characterized in that The fluid supply manifold includes a fluid exhaust manifold positioned between the first plenum and the second plenum, wherein the outlet opening is positioned at the fluid exhaust manifold.

12. The heat engine according to claim 10, characterized in that A fluid passage is formed between adjacent pairs of the plurality of first manifold portions arranged in a circumferential arrangement, wherein the fluid passage provides fluid communication between the second plenum and the third plenum.

13. The heat engine according to claim 12, characterized in that The fluid supply manifold including the plurality of first manifold portions forms a fluid flow path from the first chamber to the outlet opening, and wherein the fluid supply manifold fluidly separates the fluid flow path from the second and third plenums.

14. The heat engine according to claim 1, characterized in that The outlet opening is positioned in fluid impingement relationship with the rotor disk.

15. The heat engine according to claim 1, characterized in that The seal assembly includes a compressor discharge pressure seal positioned between the compressor section and the turbine section.

16. The heat engine according to claim 15, characterized in that The rotor disk is positioned at the compressor section.

17. The heat engine according to claim 15, characterized in that The rotor assembly includes a shaft extending to the compressor section and the turbine section, and wherein the fluid supply manifold is coupled to the shaft.

18. The heat engine according to claim 17, characterized in that The fluid supply manifold comprises a first manifold portion extending along the radial direction, and wherein the fluid supply manifold comprises a second manifold portion extending along an axial direction co-directional with the axis, and wherein the fluid supply manifold comprises a third manifold portion extending along the radial direction on the inner side of the rotor disk, wherein the third manifold portion comprises the outlet opening in fluid communication with the rotor disk of the rotor assembly.

19. The heat engine according to claim 18, characterized in that The first cavity is positioned distal to the compressor section, and wherein the second cavity is positioned proximal to the compressor section relative to the first cavity.

20. The heat engine according to claim 18, characterized in that A fluid passage is formed between adjacent pairs of a plurality of the first manifold portions arranged in a circumferential arrangement, and the fluid supply manifold including the plurality of the first manifold portions forms a fluid flow path from the first chamber to the outlet opening, and wherein the fluid supply manifold fluidically isolates the fluid flow path from a third plenum adjacent to the seal assembly opposite the second plenum.

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