Seal for a rotor

Abstract

A seal for a rotor is provided. The rotor defines an axial direction, a circumferential direction, and a radial direction. The seal includes a first flexible element coupled to the rotor. The first flexible element extends in a first direction within forty-five degrees of the axial direction.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to a seal for a rotor, such as a seal for a rotor of a gas turbine engine. BACKGROUND

[0002] Rotating machinery often includes an assembly of components having a rotor, which is a rotatable component, adjacent to a stator, which does not rotate with the rotor. The rotor of the assembly of components can sometimes have a different coefficient of thermal expansion than the stator adjacent thereto. Accordingly, the rotor and the stator are spaced apart to accommodate thermal growth of the rotor relative to the stator. However, spacing the stator apart from the rotor can result in leakage of a fluid, such as a gas or a liquid, between the stator and the rotor, which can be undesirable. Accordingly, seals are often provided to prevent the fluid from passing through the space between the rotor and the stator. The inventors of the present disclosure have proposed various configurations and devices to improve upon currently known seals. BRIEF DESCRIPTION OF DRAWINGS

[0003] A complete and enabling disclosure of the present disclosure, including the best mode thereof, to one of ordinary skill in the art is set forth in the specification in reference to the accompanying drawings, wherein:

[0004] Figure 1 is a schematic cross-sectional view of a gas turbine engine in accordance with an example embodiment.

[0005] Figure 2 is a perspective cross-sectional view of an assembly of components of a rotating machinery in accordance with an example embodiment.

[0006] Figure 3 is a perspective cross-sectional view of a portion of the assembly of components of Figure 2 in accordance with an example embodiment.

[0007] Figure 4 is a schematic cross-sectional view of the assembly of components in accordance with an example embodiment.

[0008] Figure 5 is a schematic cross-sectional view of the assembly of components in accordance with an example embodiment.

[0009] Figure 6A is a schematic cross-sectional view of the assembly of components in accordance with an example embodiment.

[0010] Figure 6B is a schematic cross-sectional view of the assembly of components of Figure 6A in accordance with an example embodiment.

[0011] Figure 7 is a schematic cross-sectional view of the assembly of components in accordance with an example embodiment. DETAILED DESCRIPTION

[0012] Reference will now be made in detail to embodiments of the present disclosure, one or more examples of which are illustrated in the drawings. The detailed description uses numerical and letter designations to refer to features in the drawings. Like or similar designations in the drawings and description have been used to refer to like or similar parts of the present disclosure.

[0013] The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other implementations. Furthermore, unless otherwise specifically noted, the description herein of any embodiment should be considered as an example of that embodiment only and not as a limitation of the disclosure.

[0014] For purposes of the description hereinafter, the terms “upper,” “lower,” “right,” “left,” “vertical,” “horizontal,” “top,” “bottom,” “lateral,” “longitudinal,” and derivatives thereof shall relate to the embodiments as they are oriented in the drawings. However, it is to be understood that the embodiments can assume various alternative orientations and, unless otherwise specifically noted, the specific

[0015] As used herein, the terms “first,” “second,” and “third” can be used interchangeably to distinguish one component from another and are not intended to signify location or importance of individual components.

[0016] The terms “forward” and “aft” refer to relative positions within a gas turbine engine or vehicle and refer to the normal operating attitude of the gas turbine engine or vehicle. For example, for a gas turbine engine, forward refers to a position closer to the engine inlet and aft refers to a position closer to the engine nozzle or exhaust.

[0017] The terms “upstream” and “downstream” refer to the relative direction 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.

[0018] The terms “coupled,” “fixed,” “attached” and like terms can refer to direct and indirect coupling, fixation, or attachment, unless otherwise specifically stated herein.

[0019] The singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.

[0020] The term “at least one of’ in the context of, for example, “at least one of A, B, and C,” is used to mean A alone, B alone, C alone, or any combination of A, B, and C.

[0021] Approximating language is applied to quantify any quantitative representation that, without being qualified, could conceivably vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as "about", "approximately", and "substantially", are not limited to the precise value specified. In at least some instances, the approximating language can correspond to the precision with which the instrument used to measure the value, or the method or machinery used to construct or manufacture the components and / or systems actually measures the value. For example, the approximating language can refer to a margin of error within 1%, 2%, 4%, 10%, 15%, or 20% of the specified value. These approximating margins can apply to individual values, either endpoint of a range, or both endpoints of a range, and / or the margin of error within a range.

[0022] Throughout the specification and claims, range limitations are combined and interchanged, such ranges are identified and include all the sub-ranges contained therein, unless context or language indicates otherwise. For example, all ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other.

[0023] The term "turbomachine" or "turbomachinery" refers to a machine comprising one or more compressors, a heat generating section (e.g., a combustion section), and one or more turbines that together produce a torque output.

[0024] The term "gas turbine engine" refers to an engine having a turbomachine as all or a portion of its power source. Example gas turbine engines include turbofan engines, turboprop engines, turbojet engines, turboshaft engines, and the like, as well as hybrid versions of one or more of these engines.

[0025] The term "combustion section" refers to any heat addition system for a turbomachine. For example, the term combustion section can refer to a section comprising one or more of a deflagration combustion assembly, a rotating detonation combustion assembly, a pulse detonation combustion assembly, or other suitable heat addition assembly. In certain example embodiments, a combustion section can include an annular combustor, a can combustor, a tubular combustor, a trapped vortex combustor (TVC), or other suitable combustion system, or combinations thereof.

[0026] The terms "low" and "high", or their respective comparative degrees (e.g., higher, lower, as applicable), when used in conjunction with a compressor, turbine, shaft, or spool component, and the like, each refer to relative speeds within an engine, unless otherwise specified. For example, "low turbine" or "low speed turbine" defines a component configured to operate at a lower rotational speed (e.g., maximum allowable rotational speed) than a "high turbine" or "high speed turbine" at the location in the engine.

[0027] As used herein, the term "unitary," "monolithic," or "one-piece" with respect to a structure refers to a structure that is formed integrally from a continuous material or group of materials without seams, connecting joints, or the like. Unitary monolithic structures described herein can be formed by additive manufacturing or, alternatively, by a casting process or the like to have the described structure.

[0028] The present disclosure relates generally to a seal for a rotor, such as a rotor of a rotating machine. The seal can be provided to prevent fluid, such as a gas or a liquid, from leaking between the rotor and a stator. In an example of a gas turbine engine, the seal can be provided to prevent hot gas from leaking between the rotor and the stator, which can be undesirable.

[0029] In at least one example, the seal can include a first flexible element and a second flexible element. The first flexible element can be provided to form an axial interface with the shroud, and the second flexible element can be provided to form a radial interface with the shroud. As can be appreciated from the discussion herein, providing an axial interface and a radial interface with the shroud can reduce the amount of fluid that leaks between the rotor and the stator.

[0030] In at least one example, the seal is coupled to the rotor and can rotate with the rotor. As the rotor rotates, the seal is subjected to a centrifugal force in a radial direction. The centrifugal force can cause the flexible elements to be pushed radially outward, causing the flexible elements to contact or closely approach the stator, which can reduce the amount of fluid that leaks between the rotor and the stator.

[0031] In at least one example, the seal can include a first flexible element and a second flexible element. When the rotating machine in which the seal is installed is operated in a relatively hot condition, the first flexible element can closely approach the stator. However, due to different thermal expansion between the rotor and the stator, the first flexible element can not closely approach the stator when the rotating machine is operated in a relatively cold condition. Accordingly, the second flexible element can be provided and positioned to closely approach the stator when the rotating machine is operated in the relatively cold condition. Providing the first flexible element that closely approaches the stator when the rotating machine is operated in the relatively hot condition and the second flexible element that closely approaches the stator when the rotating machine is operated in the relatively cold condition can allow the amount of fluid that leaks between the rotor and the stator to be reduced in both the relatively hot condition and the relatively cold condition.

[0032] In at least one example, the first flexible element of the seal can include bristles. The bristles of the first flexible element can create a curtain effect that can reduce the amount of fluid that leaks between the rotor and the stator. In addition, due to different thermal expansion rates, the bristles can allow radial and axial movement between the rotor and the stator.

[0033] Reference will now be made to the drawings wherein like numerals refer to like components throughout the several figures,Figure 1 is a schematic cross-sectional view of a gas turbine engine in accordance with example embodiments of the present disclosure. More particularly, for the embodiments of Figure 1 , the gas turbine engine is a high-bypass turbofan engine, referred to herein as "turbine engine 10." As shown, turbine engine 10 defines an axial direction A (extending parallel to a longitudinal centerline 12 for reference) and a radial direction R. Generally, turbine engine 10 includes a fan section 14 and a turbine machine 16 arranged downstream of fan section 14. Figure 1

[0034] The depicted example turbine machine 16 generally includes a substantially tubular outer casing 18 defining an annular inlet 20. Outer casing 18 encloses, in serial flow relationship: a compressor section including a booster or low pressure (LP) compressor 22 and a high pressure (HP) compressor 24; a combustion section 26; a turbine section including a high pressure (HP) turbine 28 and a low pressure (LP) turbine 30; and an ejection exhaust nozzle section 32. A high pressure (HP) shaft or spool 34 drivingly connects HP turbine 28 to HP compressor 24. A low pressure (LP) shaft or spool 36 drivingly connects LP turbine 30 to LP compressor 22. Compressor section, combustion section 26, turbine section, and ejection exhaust nozzle section 32 together define a core air flowpath 37.

[0035] For the depicted embodiment, fan section 14 includes a fan 38 having a plurality of fan blades 40 coupled to a rotor disk 42 in a spaced apart manner. As shown, fan blades 40 extend generally outwardly from rotor disk 42 along the radial direction R. Rotor disk 42 is covered by a rotatable front hub 48 having an aerodynamic profile to facilitate airflow through the plurality of fan blades 40. Additionally, example fan section 14 includes an annular fan casing or outer nacelle 50 that circumferentially surrounds at least a portion of fan 38 and / or turbine machine 16. It should be appreciated that nacelle 50 can be configured to be supported relative to turbine machine 16 by a plurality of circumferentially spaced apart outlet guide vanes 52. Moreover, a downstream section 54 of nacelle 50 can extend over an outer portion of turbine machine 16 to define a bypass airflow passage 56 therebetween.

[0036] ​During operation of the turbofan engine 10, a volume of air 58 enters the turbofan engine 10 through an associated inlet 60 of the nacelle 50 and / or fan section 14. As the volume of air 58 passes through the fan blades 40, a first portion of the air 58, as indicated by arrow 62, is directed or channeled into the bypass airflow passage 56 and a second portion of the air 58, as indicated by arrow 64, is directed or channeled into the core airflow pathway 37, or more specifically into the LP compressor 22. The ratio between the first portion of air 62 and the second portion of air 64 is commonly referred to as a bypass ratio. The pressure of the second portion of air 64 is then increased as it is channeled through the HP compressor 24 and into the combustion section 26 where it is mixed with fuel and burned to provide combustion gases 66.

[0037] The combustion gases 66 are directed through the HP turbine 28 where a portion of the thermal and / or kinetic energy from the combustion gases 66 is extracted via successive stages of HP turbine stator vanes 68 coupled to the outer casing 18 and HP turbine rotor blades 70 coupled to the HP shaft or spool 34, thus causing the HP shaft or spool 34 to rotate, thereby supporting operation of the HP compressor 24. The combustion gases 66 then pass through the LP turbine 30 where a second portion of the thermal and kinetic energy from the combustion gases 66 is extracted via successive stages of LP turbine stator vanes 72 coupled to the outer casing 18 and LP turbine rotor blades 74 coupled to the LP shaft or spool 36, thus causing the LP shaft or spool 36 to rotate, thereby supporting operation of the LP compressor 22 and / or rotation of the fan 38.

[0038] The combustion gases 66 are subsequently directed through the jet exhaust nozzle section 32 of the turbine engine 16 to provide propulsive thrust. At the same time, the pressure of the first portion of air 62 increases significantly as it is channeled through the bypass airflow passage 56 before it is exhausted from the fan nozzle exhaust section 76 of the turbofan engine 10, also providing propulsive thrust. The HP turbine 28, the LP turbine 30, and the jet exhaust nozzle section 32 at least partially define a hot gas path 78 for directing the combustion gases 66 through the turbine engine 16.

[0039] However, it should be understood that, Figure 1The exemplary turbofan engine 10 depicted is by way of example only, and in other exemplary embodiments, the turbofan engine 10 can have any other suitable configuration. For example, in other exemplary embodiments, the fan 38 can be configured as a variable-pitch fan, including for example a suitable actuation assembly for rotating a plurality of fan blades about respective pitch axes, the turbofan engine 10 can be configured as a geared turbofan engine having a reduction gear box between the low pressure shaft or spool 36 and the fan section 14, among others. It will also be appreciated that aspects of the present disclosure can be incorporated into any other suitable gas turbine engine, in other exemplary embodiments. For example, aspects of the present disclosure can be incorporated into a turboprop engine, for example, in other exemplary embodiments.

[0040] Referring now to Figure 2 , a perspective cross-sectional view of a component assembly 100 of a rotating machine, such as a turbofan engine 10 Figure 1 ) is shown, in accordance with one exemplary embodiment. Although the component assembly 100 will be frequently described in connection with the turbofan engine 10, it will be appreciated that the present disclosure is applicable to other rotating machines, such as a steam turbine.

[0041] The component assembly 100 of the rotating machine can include a rotor 120 and a stator 140. The rotor 120 can define an axial direction A, a circumferential direction C, and a radial direction R. The radial direction R is perpendicular to the axial direction A, and the circumferential direction C is defined about the axial direction A.

[0042] The rotor 120 can be configured such that it can rotate about the axial direction A. As shown, the stator 140 can extend at least partially in the circumferential direction C and at least partially about the rotor 120. Further, the stator 140 can be configured to be non-rotatable so as to remain stationary relative to other components of the rotating machine on which it is mounted.

[0043] In this example, the rotor 120 is coupled to and rotatable with the LP shaft or spool 36 of the turbofan engine 10 Figure 1 ). However, in other examples, the rotor 120 is coupled to and rotatable with the HP shaft or spool 34 of the turbofan engine 10 Figure 1 ). The stator 140 can be directly or indirectly coupled to other non-rotating components, such as a casing 160, which can at least partially surround the stator 140.

[0044] The component assembly 100 of the rotating machinery may include a seal 200. The seal 200 may be coupled to a rotor 120 and positioned between a stator 140 and the rotor 120. The seal 200 may extend partially or entirely circumferentially around the rotor 120. As will be explained in more detail, the seal 200 may be configured to prevent fluid leakage between the stator 140 and the rotor 120 by creating a curtain effect. When the rotating machinery is a gas turbine engine, such as a turbofan engine 10 (…),… Figure 1 A seal 200 can be provided to prevent hot gas from flowing from the front position (left side of the page) of the component assembly 100 to the rear position (right side of the page). More specifically, the seal 200 can prevent hot gas from flowing from the position in front of the seal 200 to the position behind the seal 200.

[0045] Now for reference Figure 3 According to an example embodiment, Figure 2 A portion of a component assembly 100 of rotating machinery is shown. In this example, a seal 200 extends from a circumferentially extending surface 122 of the rotor 120 of the component assembly 100. The seal 200 includes a first flexible element 220a. The first flexible element 220a may be an assembly of a plurality of first flexible elements 220a that partially extend around the rotor 120, but may be assembled closely together to extend completely around the rotor 120. In other examples, the first flexible element 220a is not an assembly and may extend completely around the rotor 120.

[0046] The thickness of the first flexible element 220a along the axial direction A can be from 0.5 mm to 5 mm. The first flexible element 220a may include a plurality of bristles (schematically shown as a single cross-section for clarity). Each of the plurality of bristles may be substantially cylindrical and have a diameter less than 0.5 mm, for example, between 0.15 and 0.25 mm. The diameter of each bristle may vary relative to the other bristles in the plurality of bristles. For example, bristles with smaller diameters may be located within the axial center of the plurality of bristles compared to bristles located at forward and backward axial positions. The bristles may be made of metal. For example, the bristles may be made of nickel alloy, cobalt alloy, or stainless steel. The bristles may be attached to the rotor 120 by welding or mechanical fasteners.

[0047] In other examples, the first flexible element 220a can include a plurality of circumferentially spaced apart flexible fingers. In yet other examples, the first flexible element 220a can include at least one circumferentially extending thin plate. In some embodiments, the at least one thin plate is a plurality of thin plates. Further, in some embodiments, at least one of the thin plates circumferentially overlaps another one of the thin plates. In other alternative embodiments, the first flexible element 220a includes any suitable flexible structure that enables the seal 200 to function as described herein.

[0048] As best seen in this view, the seal 200 can include a first back plate 240a. The first back plate 240a can be coupled to the rotor 120 and positioned adjacent to the first flexible element 220a. The first back plate 240a can extend circumferentially partially or completely around the rotor 120. In this example, the first back plate 240a is positioned forward of the first flexible element 220a. However, in other examples, the first back plate 240a is positioned rearward of the first flexible element 220a. The first back plate 240a can be provided to prevent the first flexible element 220a from being damaged and / or plastically deformed as it is subjected to centrifugal loads as the rotor 120 rotates.

[0049] As Figure 3 As best seen, the first back plate 240a can at least partially support, i.e., bear, a portion of the load of the first flexible element 220a. More specifically, the first back plate 240a can be curved such that it is offset from the radial direction R. For example, the first back plate 240a can have a rear surface that extends in a first direction 222a that forms a first angle 223a with the radial direction R and the first direction 222a, the first angle 223a being forty-five degrees or less, e.g., thirty-five degrees or less, e.g., fifteen degrees or less. Likewise, the first flexible element 220a can be curved such that it is offset from the radial direction R. For example, the first flexible element 220a can also extend in the first direction 222a and can be pressed against the first back plate 240a. Although shown as extending toward the rear side of the component assembly 100, it should be understood that the first flexible element 220a and the first back plate 240a can extend toward the front side of the component assembly 100.

[0050] In some examples, the seal 200, which may include a first backplate 240a and / or a first flexible element 220a, may be configured identically or similarly to the seal 100, which may include a retaining plate 106 and / or a flexible element 110, in U.S. Application No. 14 / 869,538, filed September 29, 2015 (the entire contents of which are incorporated herein by reference). In some examples, the seal 200, which may include a first backplate 240a and / or a first flexible element 220a, may be configured identically or similarly to the seal 100, which may include a retaining plate 122 and / or a flexible element 124, in U.S. Application No. 15 / 248,161, filed August 26, 2016 (the entire contents of which are incorporated herein by reference).

[0051] Now for reference Figure 4 A schematic cross-sectional view of a component assembly 100 having a seal 200 is depicted according to an example embodiment. In this example, the seal 200 includes a first flexible element 220a, a second flexible element 220b, and a third flexible element 220c. The first flexible element 220a, the second flexible element 220b, and the third flexible element 220c can be referenced... Figure 3 The first flexible element 220a described is configured identically or similarly. Although not shown, the seal 200 may also include a backing plate for each of the first flexible element 220a, the second flexible element 220b, and the third flexible element 220c, each of which may be related to the reference. Figure 3 The first backplate 240a is configured in the same or similar manner.

[0052] The first flexible element 220a, the second flexible element 220b, and the third flexible element 220c can each be coupled to the rotor 120 and can each extend circumferentially, partially or completely, about the axial direction A. The first flexible element 220a can extend in a first direction 222a, which forms a first angle 223a between the radial direction R and the first direction 222a. The first angle 223a is forty-five degrees or less, for example, thirty-five degrees or less, for example, fifteen degrees or less. In this example, the first flexible element 220a extends in a forward direction (left side of the page), but in other examples, it can extend in a backward direction (right side of the page). The second flexible element 220b can extend in a second direction 222b, and the third flexible element 220c can extend in a third direction 222c. In this example, the second direction 222b and the third direction 222c are the same as the axial direction; however, the second direction 222b and / or the third direction 222c can deviate from the axial direction A. For example, the second direction 222b can deviate from the axial direction A, such that a second angle 223b is formed between the axial direction A and the second direction 222b (see...). Figure 5), the second angle 223b is forty-five degrees or less, such as thirty-five degrees or less, such as fifteen degrees or less. Similarly, the third direction 222c can be offset from the axial direction A such that a third angle 223c (see Figure 5 ), the third angle 223c is forty-five degrees or less, such as thirty-five degrees or less, such as fifteen degrees or less. In this example, the second flexible element 220b extends in the forward direction and the third flexible element 220c extends in the rearward direction. Further, the second angle 223b or the third angle 223c can be negative or positive such that the second direction 222b or the third direction 222c can be in the inward direction.

[0053] As will be explained in more detail, the first flexible element 220a can be disposed to form a radial interface with the stator 140 to prevent fluid leakage between the rotor 120 and the stator 140. Similarly, the second flexible element 220b and / or the third flexible element 220c can be disposed to form an axial interface with the stator 140 to prevent fluid leakage between the rotor 120 and the stator 140. In some examples (which will also be explained in more detail), the first flexible element 220a, the second flexible element 220b, and / or the third flexible element 220c can be disposed to form an axial interface and a radial interface with the stator 140 to prevent fluid leakage between the rotor 120 and the stator.

[0054] Reference is now made to Figure 5 According to example embodiments, a schematic cross-sectional view of a component assembly 100 having a seal 200 is depicted. In this example, the seal 200 includes a first flexible element 220a, a first backplate 240a, a second flexible element 220b, and a second backplate 240b. In other examples, the seal 200 does not include the first backplate 240a and / or the second backplate 240b. The first flexible element 220a, the first backplate 240a, the second flexible element 220b, and the second backplate 240b can be configured similarly or the same as the examples provided with reference to Figure 3 and Figure 4 are provided.

[0055] In this example, the stator 140 includes a first protrusion 141a extending radially inward from the stator 140 and toward the rotor 120. Although the first protrusion 141a has a rectangular cross-section in this example, it should be understood that the first protrusion 141a can have any shape. In this example, the first protrusion 141a extends radially inward from an axially and circumferentially extending surface 142 of the stator 140. The first protrusion 141a defines a first notch 143a and a second notch 143b. The first notch 143a and the second notch 143b are each defined at a location where a root end 144 of the first protrusion 141a joins the axially and circumferentially extending surface 142 of the stator 140. More specifically, the first notch 143a and the second notch 143b are each defined at a location where the axially and circumferentially extending surface 142 of the stator 140 intersects a radially extending surface 145 of the first protrusion 141a. Although shown as sharp corners, it should be understood that the first notch 143a and the second notch 143b can be rounded, chamfered, or any other shape. Further, in this example, the first protrusion 141a is located between the first flexible element 220a and the second flexible element 220b.

[0056] As shown, the first back plate 240a, the first flexible element 220a, the second back plate 240b, and the second flexible element 220b each extend toward the first protrusion 141a. In other words, the first flexible element 220a and the first back plate 240a each extend in a first direction 222a that is toward a rearward direction when the first protrusion 141a is behind the first flexible element 220a and the first back plate 240a; the second flexible element 220b and the second back plate 240b each extend in a second direction 222b that is toward a forward direction when the first protrusion 141a is in front of the second flexible element 220b and the second back plate 240b.

[0057] The first flexible element 220a and the second flexible element 220b can each have a tip 221 that is a terminal end of the respective flexible element 220a, 220b. The tip 221 can be shaped to conform to a shape of the respective notch 143a or 143b of the first protrusion 141a. As shown, the tip 221 has a sharp corner tip to conform to the sharp corners of the notches 143a, 143b of the first protrusion 141a. However, when the first notch 143a and the second notch 143b are, for example, chamfered, the tip 221 of the first flexible element 220a and the second flexible element 220b can each have an outer rounded or semi-outer rounded shape so that they are also chamfered. Similarly, when the first notch 143a and the second notch 143b are, for example, bevelled, the tip 221 of the first flexible element 220a and the second flexible element 220b can also include a bevel to conform to the shape of the bevelled corners.

[0058] As noted above, the rotor 120 and the stator 140 can have different coefficients of thermal expansion and can move axially and / or radially relative to one another. Accordingly, the seal 200 can be configured such that the tip 221 of one of the first or second flexible elements 220a, 220b is configured to be positioned close to its respective notch 143a, 143b when the component assembly 100 is operated in a relatively hot state, and configured such that the tip 221 of the other of the first or second flexible elements 220a, 220b is configured to be positioned close to its respective notch 143a, 143b when the component assembly 100 is operated in a relatively cold state.

[0059] For example, as shown, a first distance Dl from the tip 221 of the first flexible element 220a to the first protrusion 141a can be zero, such that when the component assembly 100 is operated in a relatively hot state, it contacts or is closely proximate to the first notch 143a, e.g., within 3 mm of the first notch 143a, e.g., within 2 mm, e.g., within 1 mm, while a second distance D2 from the tip 221 of the second flexible element 220b to the first protrusion 141a can be greater than the first distance Dl. For example, the second distance D2 can be at least 1 mm and at most 10 mm, e.g., at least 2 mm and at most 10 mm, e.g., at least 3 mm and at most 10 mm, when the component assembly 100 is operated in a relatively hot state.

[0060] Conversely, and not depicted, the second distance D2 from the tip 221 of the second flexible element 220b to the first protrusion 141a can be zero, such that when the component assembly 100 is operated in a relatively cold state, it contacts or is closely proximate to the second notch 143b, e.g., within 3 mm of the second notch 143b, e.g., within 2 mm, e.g., within 1 mm, while the first distance Dl from the tip 221 of the first flexible element 220a to the first protrusion 141a can be greater than the second distance D2. For example, the first distance Dl can be at least 1 mm and at most 10 mm, e.g., at least 2 mm and at most 10 mm, e.g., at least 3 mm and at most 10 mm, when the component assembly 100 is operated in a relatively cold state.

[0061] Referring now to FIGS. 6a and 6b, schematic cross-sectional views of a component assembly 100 having a seal 200 are depicted, according to example embodiments. More specifically, FIG. 6a depicts the component assembly 100 when the rotating machine is operated in a relatively hot state, while FIG. 6b depicts the component assembly 100 when the rotating machine is operated in a relatively cold state. The seal 200 of FIGS. 6a and 6b can be similar to the seal 200 of FIGS. 1-5, and the component assembly 100 of FIGS. 6a and 6b can be similar to the component assembly 100 of FIGS. 1-5. Figure 5The seal 200 is configured identically or similarly to the seal 200 of the component assembly 100 of FIG. 1; however, in this example, the seal 200 includes only a first backplate 240a and a first flexible element 220a. However, in other examples, the seal 200 includes more than a single first backplate 240a and first flexible element 220a. As best seen in these views, the first flexible element 220a of the seal 200 is positioned proximate to the first notch 143a defined by the first protrusion 141a to prevent fluid, such as hot gas, from flowing from a location in front of the seal 200 to a location behind the seal 200. Moreover, by positioning the tip 221 of the first flexible element 220a proximate to the first notch 143a defined by the first protrusion 141a, any gas passing through the seal 200 follows a tortuous path 150.

[0062] Moreover, as mentioned, the rotor 120 and the stator 140 can have different coefficients of thermal expansion and can move axially and / or radially relative to one another. Accordingly, the seal 200 can be configured such that the tip 221 of the first flexible element 220a is configured to be positioned proximate to its respective first notch 143a when the component assembly 100 is operated in a relatively hot state, and configured such that the tip 221 of the first flexible element 220a is configured to be positioned further away from its respective first notch 143a when the component assembly 100 is operated in a relatively cold state.

[0063] For example, as depicted in FIG. 6a, a first distance Dl from the tip 221 of the first flexible element 220a to the first protrusion 141a along the axial direction A can be zero such that it contacts or is in close proximity to the first notch 143a when the component assembly 100 is operated in a relatively hot state, e.g., within 3 mm of the first notch 143a, such as within 2 mm, such as within 1 mm, and a second distance D2 from the tip 221 of the first flexible element 220a to the stator 140 along the radial direction R can be zero such that it contacts or is in close proximity to the stator 140 when the component assembly 100 is operated in a relatively hot state, e.g., within 3 mm of the stator 140, such as within 2 mm, such as within 1 mm.

[0064] Conversely, as depicted in FIG. 6b, the first distance Dl can be greater when the component assembly 100 is operated in a relatively cold state (FIG. 6b) than when the component assembly 100 is operated in a relatively hot state (FIG. 6a). Moreover, the second distance D2 can be greater when the component assembly 100 is operated in a relatively cold state (FIG. 6b) than when the component assembly 100 is operated in a relatively hot state (FIG. 6a). In some examples, the first distance Dl and / or the second distance D2 can be at least 1 mm and at most 10 mm, such as at least 2 mm and at most 10 mm, such as at least 3 mm and at most 10 mm, when the component assembly 100 is operated in a relatively cold state.

[0065] Briefly returning reference to FIG. 6a, the first flexible element 220a can form an axial interface and a radial interface with the stator 140 to prevent fluid leakage between the rotor 120 and the stator 140. More specifically, the tip 221 of the first flexible element 220a can form an axial interface with the radially extending surface 145 of the first protrusion 141a of the stator 140, and the tip 221 of the first flexible element 220a can form a radial interface with the circumferentially extending surface 142 of the stator 140. As used herein, an “interface” does not necessarily imply that contact must occur. Rather, the formation of an interface can occur when the first flexible element 220a is in contact with the stator 140 or when the first flexible element 220a is in close proximity to the stator 140. The axial interface and the radial interface between the first flexible element 220a and the stator 140 can prevent fluid leakage between the first flexible element 220a and the stator 140.

[0066] Further, as best seen in the views of FIGS. 6a and 6b, the first notch should be sized to accommodate the different first distance D1 and second distance D2 when the component assembly is operated in the relatively cold state and when the component assembly 100 is operated in the relatively hot state. For example, when the component assembly 100 is operated in the relatively cold state (FIG. 6b), the first protrusion 141a should have a radial length L that is greater than the second distance D2.

[0067] Reference is now made to Figure 7 , according to example embodiments, a schematic cross-sectional view of a component assembly 100 having a seal 200 is depicted. Figure 7 The seal 200 of FIG. 6a can be configured the same as or similar to the seal 200 of Figure 5 ; however, in this example, the first flexible element 220a extends in a first direction 222a toward a front side of the seal 200 (left side of the page), and the second flexible element 220b extends in a second direction 222b toward a back side of the seal 200 (right side of the page). Further, neither the first flexible element 220a nor the second flexible element 220b extends toward a notch defined by a protrusion (e.g., the third protrusion 141c) that is axially positioned between the first flexible element 220a and the second flexible element 220b. Rather, the first flexible element 220a extends toward the first notch 143a defined by the first protrusion 141a that is axially positioned in front of the first flexible element 220a, and the second flexible element 220b extends toward the second notch 143b defined by the second protrusion 141b that is axially positioned behind the second flexible element 220b.

[0068] Further, as shown, the seal 200 can include a first backplate 240a positioned between the first and second flexible elements 220a, 220b. Although the first backplate 240a in this example is a unitary component that provides support for both the first and second flexible elements 220a, 220b, in other examples, the seal 200 can include two separate backplates, each supporting a different one of the first and second flexible elements 220a, 220b.

[0069] In this example, a first distance Dl from the tip 221 of the first flexible element 220a to the first protrusion 141a can be zero, such that when the component assembly 100 is operating in a relatively cold state, it contacts or is in close proximity to the first notch 143a, e.g., within 3 mm of the first notch 143a, such as within 2 mm, such as within 1 mm, while a second distance D2 from the tip 221 of the second flexible element 220b to the second protrusion 141b can be greater than the first distance Dl. For example, the second distance D2 can be at least 1 mm and at most 10 mm, such as at least 2 mm and at most 10 mm, such as at least 3 mm and at most 10 mm, when the component assembly 100 is operating in a relatively cold state.

[0070] Conversely, and not depicted, the second distance D2 from the tip 221 of the second flexible element 220b to the second protrusion 141b can be zero, such that when the component assembly 100 is operating in a relatively hot state, it contacts or is in close proximity to the second notch 143b, e.g., within 3 mm of the second notch 143b, such as within 2 mm, such as within 1 mm, while the first distance Dl from the tip 221 of the first flexible element 220a to the first protrusion 141a can be greater than the second distance D2. For example, the first distance Dl can be at least 1 mm and at most 10 mm, such as at least 2 mm and at most 10 mm, such as at least 3 mm and at most 10 mm, when the component assembly 100 is operating in a relatively hot state.

[0071] Further, the seal 200 can be configured such that the tips 221 of the first and second flexible elements 220a, 220b are configured to be approximately equidistant from their respective notches 143a, 143b when the component assembly 100 is operating at a median temperature, which is intermediate the relatively hot and cold states. The relatively hot state can be the hottest temperature experienced by the component assembly 100 when the component assembly 100 is operating normally, while the relatively cold state can be the coldest temperature experienced by the component assembly 100 when the component assembly 100 is operating normally. In the example of a gas turbine engine, the relatively hot state can be experienced when an aircraft in which the gas turbine engine is installed is taking off, while the relatively cold state can be experienced when the gas turbine engine is starting up and is located on the ground.

[0072] As mentioned, in this example, the stator 140 also includes a third protrusion 141c axially positioned between the first flexible element 220a and the second flexible element 220b. The third protrusion 141c axially positioned between the first flexible element 220a and the second flexible element 220b can partially define the tortuous path 150. Also, as mentioned, the rate of thermal expansion between the stator 140 and the rotor 120 can be different. As such, the rotor 120 can move closer to the stator 140 when the component assembly 100 is operating in a relatively hot state, and the rotor 120 can move further away from the stator 140 when the component assembly 100 is operating in a relatively cold state. A third distance D3 between the third protrusion 141c and the first backplate 240a, or between the third protrusion 141c and the rotor 120 when the first backplate 240a is not radially positioned between the third protrusion 141c and the first backplate 240a, can be minimized when the component assembly 100 is operating in a relatively hot state. For example, the third distance D3 can be less than 10 mm, such as less than 5 mm, such as less than 4 mm, when the component assembly 100 is operating in a relatively hot state. Minimizing the third distance D3 when the component assembly 100 is operating in a relatively hot state can further reduce the amount of fluid (e.g., hot gas) that can pass through the seal 200 by increasing the number of curves and the slope of the curves on the tortuous path 150.

[0073] This written description uses examples to disclose the disclosure, including the best mode, and also to enable any person skilled in the art to practice the disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and can include other examples that occur to those skilled in the art. Such other examples are intended to fall within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

[0074] Further aspects are provided by the subject matter of the following clauses:

[0075] A seal for a rotor, the seal to prevent gas from flowing from a location forward of the seal to a location rearward of the seal, the rotor defining an axial direction, a circumferential direction, and a radial direction, the seal comprising: a first flexible element coupled to the rotor and extending in a first direction within forty-five degrees of the axial direction; and a second flexible element coupled to the rotor and extending in a second direction within forty-five degrees of the axial direction or within forty-five degrees of the radial direction.

[0076] A seal according to one or more of the clauses, wherein the first flexible element includes a first plurality of bristles and the second flexible element includes a second plurality of bristles.

[0077] A seal according to one or more of the clauses, wherein the second direction is within forty-five degrees of the radial direction and the seal includes a third flexible element coupled to the rotor and extending in a third direction within forty-five degrees of the axial direction, wherein the first flexible element extends in a forward direction and the third flexible element extends in a rearward direction.

[0078] A rotary machine comprising: a rotor defining an axial direction, a circumferential direction, and a radial direction; a stator extending at least partially in the circumferential direction and at least partially around the rotor; and a seal coupled to the rotor and positioned between the stator and the rotor, the seal comprising: a first flexible element coupled to the rotor and extending in a first direction within forty-five degrees of the axial direction; and a second flexible element coupled to the rotor and extending in a second direction within forty-five degrees of the axial direction or within forty-five degrees of the radial direction.

[0079] A rotary machine according to one or more of the clauses, wherein the first flexible element includes a first plurality of bristles and the second flexible element includes a second plurality of bristles.

[0080] A rotary machine according to one or more of the clauses, wherein the second direction is within forty-five degrees of the radial direction and the seal includes a third flexible element coupled to the rotor and extending in a third direction within forty-five degrees of the axial direction, wherein the first flexible element extends in a forward direction and the third flexible element extends in a rearward direction.

[0081] A rotary machine comprising: a rotor defining an axial direction, a circumferential direction, and a radial direction; a stator extending at least partially in the circumferential direction and at least partially around the rotor, the stator including a first protrusion defining a first notch; and a seal coupled to the rotor and positioned between the stator and the rotor, the seal comprising: a first flexible element having a first tip, wherein the first tip is positioned in close proximity to the first notch.

[0082] A rotating machine according to one or more of the clauses, wherein the rotating machine is a gas turbine engine having a compressor section, a combustion section, a turbine section, and a shaft coupling the compressor section to the turbine section, wherein the rotor is coupled to the shaft and rotatable therewith.

[0083] A rotating machine according to one or more of the clauses, wherein the stator has an axially and circumferentially extending surface, and the first protrusion has a radially extending surface, wherein the first recess is defined at a location where the axially and circumferentially extending surface of the stator intersects the radially extending surface of the first protrusion.

[0084] A rotating machine according to one or more of the clauses, wherein the first tip has a first shape that conforms to a shape of the first recess.

[0085] A rotating machine according to one or more of the clauses, wherein the first flexible element includes a plurality of bristles.

[0086] A rotating machine according to one or more of the clauses, wherein a first distance is defined between the first tip of the first flexible element and the first recess, wherein the first distance is greater than or equal to zero millimeters (mm) and less than or equal to 3 mm.

[0087] A rotating machine according to one or more of the clauses, wherein the first distance is greater than or equal to zero mm and less than or equal to 3 mm when the rotating machine is operated in a relatively hot state, wherein the first protrusion defines a second recess, wherein the seal includes a second flexible element having a second tip, wherein a second distance is defined between the second tip of the second flexible element and the second recess, wherein the second distance is greater than or equal to zero mm and less than or equal to 3 mm when the rotating machine is operated in a relatively cold state, wherein the first distance is less than the second distance when the rotating machine is operated in the relatively hot state, and the first distance is greater than the second distance when the rotating machine is operated in the relatively cold state.

[0088] A rotating machine according to one or more of the clauses, wherein the first protrusion is positioned between the first flexible element and the second flexible element, and the first flexible element extends in a first direction within forty-five degrees of the radial direction, and the second flexible element extends in a second direction within forty-five degrees of the radial direction.

[0089] The rotating machine according to one or more of these articles, wherein the first distance is greater than or equal to zero mm and less than or equal to 3 mm when the rotating machine is operated in a relatively cold condition, wherein the stator includes a second protrusion defining a second notch, wherein the seal includes a second flexible element having a second tip, wherein a second distance is defined between the second tip of the second flexible element and the second notch, wherein the second distance is greater than or equal to zero mm and less than or equal to 3 mm when the rotating machine is operated in a relatively hot condition, wherein the first distance is less than the second distance when the rotating machine is operated in the relatively cold condition and the first distance is greater than the second distance when the rotating machine is operated in the relatively hot condition.

[0090] The rotating machine according to one or more of these articles, wherein the first flexible element and the second flexible element are positioned between the first protrusion and the second protrusion.

[0091] The rotating machine according to one or more of these articles, wherein the stator includes a third protrusion axially positioned between the first flexible element and the second flexible element.

[0092] The rotating machine according to one or more of these articles, wherein the first distance is greater than or equal to zero mm and less than or equal to 3 mm when the rotating machine is operated in a relatively hot condition, and the first tip of the first flexible element is further from the first notch when the rotating machine is operated in a relatively cold condition, wherein the first distance is an axial distance.

[0093] The rotating machine according to one or more of these articles, wherein the first distance is greater than or equal to 1 mm when the rotating machine is operated in a relatively cold condition.

[0094] The rotating machine according to one or more of these articles, wherein the second distance is defined between the stator and the first tip of the first flexible element, wherein a radial length of the first protrusion is greater than the second distance.

Claims

1. A rotating machine, characterized in that, include: A rotor, the rotor defining an axial direction, a circumferential direction and a radial direction; A stator that extends at least partially in the circumferential direction and at least partially around the rotor, the stator including a first protrusion defining a first recess and a second recess; and A seal, coupled to the rotor and positioned between the stator and the rotor, the seal comprising: A first flexible element having a first tip positioned close to a first notch, wherein a first distance is defined between the first tip and the first notch of the first flexible element, wherein when the rotating machinery operates in a relatively hot state, the first distance is greater than or equal to 0 mm and less than or equal to 3 mm. A second flexible element having a second tip, wherein a second distance is defined between the second tip and the second notch of the second flexible element, wherein when the rotating machinery operates in a relatively cold state, the second distance is greater than or equal to 0 mm and less than or equal to 3 mm, and When the rotating machinery operates in a relatively hot state, the first distance is less than the second distance, and when the rotating machinery operates in a relatively cold state, the first distance is greater than the second distance.

2. The rotating machinery according to claim 1, characterized in that, The rotating machinery described therein is a gas turbine engine, which has a compressor section, a combustion section, a turbine section, and a shaft that connects the compressor section to the turbine section, wherein the rotor is connected to the shaft and is capable of rotating with the shaft.

3. The rotating machinery according to claim 1, characterized in that, The stator has axial and circumferential extending surfaces, and the first protrusion has a radial extending surface, wherein the first notch is defined at the location where the axial and circumferential extending surfaces of the stator intersect the radial extending surface of the first protrusion.

4. The rotating machinery according to claim 1, characterized in that, The first tip has a first shape that conforms to the shape of the first notch.

5. The rotating machinery according to claim 1, characterized in that, The first flexible element includes multiple bristles.

6. The rotating machinery according to claim 1, characterized in that, The first protrusion is positioned between the first flexible element and the second flexible element, and the first flexible element extends in a first direction within 45 degrees of the radial direction, and the second flexible element extends in a second direction within 45 degrees of the radial direction.

7. The rotating machinery according to claim 1, characterized in that, When the rotating machinery operates in the relatively cold state, the first tip of the first flexible element is further away from the first notch, wherein the first distance is an axial distance.

8. The rotating machinery according to claim 7, characterized in that, When the rotating machinery is operating in the relatively cold state, the first distance is greater than 3 mm and less than or equal to 10 mm.

9. The rotating machinery according to claim 7, characterized in that, The third distance is defined between the stator and the first tip of the first flexible element, and the third distance is a radial distance, wherein the radial length of the first protrusion is greater than the third distance.

10. A seal for use in rotating machinery according to claim 1, the seal preventing gas from flowing from a position in front of the seal to a position behind the seal, the rotor defining an axial direction, a circumferential direction, and a radial direction, characterized in that, The sealing element includes: A first flexible element, the first flexible element being coupled to the rotor and extending in a first direction within forty-five degrees of the axial direction; and A second flexible element is coupled to the rotor and extends in a second direction within 45 degrees of either the axial direction or the radial direction.

11. The seal according to claim 10, characterized in that, The first flexible element includes a first plurality of bristles, and the second flexible element includes a second plurality of bristles.

12. The seal according to claim 10, characterized in that, The second direction is within 45 degrees of the radial direction, and the seal includes a third flexible element coupled to the rotor and extending upward within 45 degrees of the axial direction, wherein the first flexible element extends in a forward direction and the third flexible element extends in a backward direction.

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