Brush Seal Fabrication via Helical Plate Drum Winding

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Solution Overview

Problem

Previous methods for fabricating brush seals are inefficient and imprecise, being labor-intensive and wasteful of materials, with manual techniques failing to achieve precise spacing and angle of wire bristles.

Innovation Solution

A method and system involving a drum member with alignment features to secure and bend plate members to a helical shape, winding wire around them, and precise bonding and cutting to form a brush seal assembly with controlled bristle length and spacing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If manual techniques are used to fabricate brush seals, then ease of manufacture is improved, but manufacturing precision deteriorates

Engineering Contradiction:

Improveease of manufactureVSAvoidmanufacturing precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent replaces manual mechanical techniques with an automated drum-based fabrication system. The drum member with alignment portions automatically positions and secures plate members, winds wire bristles with precise spacing, and controls bristle orientation. This mechanical automation system substitutes manual operations while achieving superior manufacturing precision for bristle spacing and angle.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Device complexity

If manual techniques are used to fabricate brush seals, then device complexity is reduced, but productivity deteriorates

Engineering Contradiction:

Improvedevice complexityVSAvoidproductivity

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The patent combines multiple fabrication operations into a single integrated drum-based system. The drum member simultaneously performs plate member positioning, wire bristle winding, spacing control, and orientation alignment in one continuous process. This merging of operations significantly improves productivity compared to sequential manual techniques while the modular drum design keeps device complexity manageable.

Inventive Principle:

Principle #5Merging (Combining)

3Loss of substance

If manual techniques are used to fabricate brush seals, then material waste is reduced, but manufacturing precision deteriorates

Engineering Contradiction:

Improvematerial wasteVSAvoidmanufacturing precision

Core Design Contradiction:

Loss of substanceVSManufacturing precision

Solution Approach 1:

The patent employs preliminary action by pre-positioning plate members on the drum using alignment portions before wire bristle winding begins. The alignment portions pre-establish the correct spacing and orientation, ensuring that wire is wound precisely where needed. This preliminary positioning prevents material waste from incorrect bristle placement while achieving high manufacturing precision for bristle spacing and angle.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS8925199B2Systems and methods and apparatus involving fabricating brush seals

Publication Date: 2015.01.06 GE INFRASTRUCTURE TECH LLC

AI summary

A method for fabricating a brush seal assembly comprising, bending a first plate member to a helical shape, bending a second plate member to a helical shape, securing the first plate member to a drum, winding a wire material around the drum and the first plate member, securing the second plate member to the drum, attaching the second plate member and the first plate member to the wire, and cutting the wire to define a bristle length.