Multi-Stage Brush Seal Bypass for Pressure Distribution
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Solution Overview
Problem
Conventional multi-stage brush seals in gas turbine engines suffer from uneven pressure distribution, leading to rapid wear and reduced durability of the most-downstream seal element, resulting in premature failure and increased maintenance costs.
Innovation Solution
A multi-stage brush seal apparatus with a bypass mechanism that connects intermediate zones to the low-pressure zone, reducing pressure on downstream seal elements and incorporating labyrinth seals for enhanced reliability, along with a control unit to manage fluid flow and pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a multi-stage brush seal is used to seal the channel between high pressure zone and low pressure zone, then the sealing effectiveness is improved, but the pressure distribution becomes uneven causing the most-downstream brush seal element to be subjected to highest pressure and wear out quickly
Solution Approach 1:
The invention divides the sealing channel into multiple stages with intermediate zones, allowing the pressure to be distributed across multiple brush seal elements rather than concentrated on the most-downstream element. This segmentation of the sealing function enables each brush seal element to handle a more balanced pressure load.
Solution Approach 2:
The invention introduces intermediate zones as intermediary chambers between the high pressure zone and low pressure zone. These intermediate zones act as mediators that distribute the pressure gradient across multiple brush seal elements, preventing the most-downstream element from bearing the full pressure difference.
2Reliability
If brush seal elements are arranged in series from high pressure zone to low pressure zone, then the sealing function is enhanced, but the most-downstream brush seal element is exposed to highest pressure causing rapid wear and premature failure
Solution Approach 1:
The sealing channel is segmented into multiple stages with intermediate zones, distributing the compressed air volume flow control across multiple brush seal elements. This prevents any single element, particularly the most-downstream one, from handling the entire volume flow and associated pressure load.
Solution Approach 2:
The invention creates a dynamic pressure distribution system where the intermediate zones allow the pressure and volume flow to be progressively managed across multiple stages. This dynamic arrangement ensures that pressure buildup does not concentrate on the most-downstream element.
3Ease of manufacture
If conventional labyrinth seals are used to minimize compressed air waste, then the sealing is economical and reliable, but a considerable amount of compressed air is still leaked into the atmosphere
Solution Approach 1:
The invention employs pneumatic principles by using brush seal elements with wire bristles that create a flexible barrier to compressed air flow. The multi-stage arrangement with intermediate zones utilizes pneumatic pressure distribution to minimize air leakage while maintaining economic feasibility compared to more complex sealing systems.
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
The solution extends the operational life of brush seal elements, enhances the durability and reliability of the sealing mechanism, and reduces maintenance costs by evenly distributing pressure across all seal elements, thereby improving the overall performance of gas turbine engines.
Implementation Method 1
a non-contact brush seal element with wire bristles
Implementation Method 2
a bypass fluidly connecting the intermediate zone to the low pressure zone, allowing a fluid in the intermediate zone to flow in part through the bypass to the low pressure zone
Data Source
AI summary
An apparatus is provided for sealing a channel fluidly connecting between a high pressure zone and a low pressure zone. The apparatus has at least two brush seal elements provided in the channel in series in a direction from the high pressure zone toward the low pressure zone to define an intermediate zone between the brush seal elements. The intermediate zone is fluidly connected to the low pressure zone through a bypass or passage, allowing a fluid in the intermediate zone to flow in part through the bypass to the low pressure zone.