Airfoil Angled Cooling Channels Debris Trapping

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Solution Overview

Problem

Conventional dual-wall cooling configurations in gas turbine engines often trap particulate debris within the coolant flow pathways due to the alignment of rails in a chordal direction, leading to reduced cooling efficiency and potential damage from centrifugal forces.

Innovation Solution

The implementation of angled cooling channels with rails oriented away from the chordal direction, combined with a wedge-shaped region and multiple cooling circuits, promotes the dislodging of debris and enhances heat transfer efficiency by directing coolant through angled channels that extend along both chordal and radial components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If rails are aligned in a chordal direction for dual-wall cooling, then cooling coverage is improved, but particulate debris is trapped within the coolant flow pathways

Engineering Contradiction:

Improvecooling coverageVSAvoidparticulate debris trapping

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

The patent transitions from conventional chordal cooling channels to three-dimensional angled cooling channels that extend in both chordal and radial directions. This dimensional change allows coolant to flow along angled paths rather than being constrained to planar chordal trajectories, enabling the coolant to absorb heat more effectively while preventing particulate debris from becoming trapped in the flow pathways.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The patent modifies the geometric parameters of the cooling channels by introducing angular orientation relative to the chordal direction. The cooling channels are configured at specific angles rather than aligned purely chordally, which changes the flow dynamics and heat transfer characteristics. This parameter change enables simultaneous achievement of improved cooling coverage and debris-free flow pathways.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If conventional dual-wall cooling configurations are used, then manufacturing simplicity is maintained, but cooling efficiency is reduced due to debris trapping

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidcooling efficiency

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent divides the cooling system into multiple independent cooling circuits rather than using a single conventional dual-wall configuration. Each cooling circuit operates independently with its own angled cooling channels, allowing for modular manufacturing and assembly. This segmentation approach maintains manufacturing feasibility while significantly improving cooling efficiency by eliminating debris trapping issues.

Inventive Principle:

Principle #1Segmentation

3Use of energy by moving object

If coolant flows through conventional cooling channels, then heat transfer occurs, but debris accumulation reduces cooling effectiveness

Engineering Contradiction:

Improveheat transferVSAvoidcooling effectiveness

Core Design Contradiction:

Use of energy by moving objectVSLoss of energy

Solution Approach 1:

The patent ensures continuous, uninterrupted coolant flow through the angled cooling channels by designing pathways that prevent debris accumulation. The angled configuration maintains steady flow conditions without the interruptions caused by debris blockages, allowing continuous heat transfer from the airfoil surfaces to the coolant throughout the entire cooling process.

Inventive Principle:

Principle #20Continuity of useful action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This configuration minimizes particle trapping, improves cooling efficiency by allowing coolant to absorb more heat before exiting, and maintains the airfoil's surfaces free of debris, thereby enhancing the performance and longevity of gas turbine engine components.

Implementation Method 1

The coolant may provide heat transfer and cooling as it traverses the flow pathway before exiting

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 2

the centrifugal force to which the airfoil (e.g., turbine blade) is exposed can increase the number of impacts, particularly on the radially-inward facing side walls, leading to trapped particles

Methodology Applied

Scientific EffectCentrifugal force: Centrifugal Force

Data Source

PatentUS11459901B1Airfoil with dual-wall cooling and angled cooling channels

Publication Date: 2022.10.04 ROLLS ROYCE CORP

AI summary

An airfoil with dual-wall cooling for a gas turbine engine comprises a spar having a pressure side wall and a suction side wall meeting at a leading edge and a trailing edge of the airfoil. An interior of the spar comprises a coolant cavity. The suction side wall includes an arrangement of rails on an outer surface thereof, where each rail extends along a non-chordal direction and terminates at or near the trailing edge. The airfoil also comprises a suction side coversheet overlying the suction side wall, where an inner surface of the suction side coversheet is in contact with the arrangement of rails so as to define a plurality of angled channels between the suction side wall and the suction side coversheet. The suction side wall also comprises inlet holes in fluid communication with the coolant cavity for feeding coolant to the angled channels, and the arrangement of rails is configured to direct the coolant through the angled channels and toward the trailing edge of the airfoil.