Brush Seal Assembly Retaining Ring Manufacturing
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Solution Overview
Problem
The current brush seal assembly and manufacturing process are costly due to the need for machining multiple perimeter weld beads, which increases the complexity and expense of the fixtures and machining processes.
Innovation Solution
A brush seal assembly that eliminates the need for perimeter welds by using a retaining ring to secure the bristle assembly and plates, where the retaining ring is pressed into the bristle assembly, eliminating the requirement for machining the weld beads and reducing the number of welds needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If perimeter weld beads are used to secure bristles and plates, then the bristle assembly is securely joined, but machining costs and fixture complexity increase
Solution Approach 1:
The patent extracts and eliminates the perimeter weld bead from the brush seal assembly design. Instead of welding bristles to form a perimeter weld bead that requires subsequent machining, the invention uses individual bristles that are directly inserted into the retainer, removing the unnecessary welding and machining operations entirely.
Solution Approach 2:
The patent segments the bristle assembly into individual bristle elements rather than a welded perimeter structure. Each bristle is independently positioned and secured in the retainer, eliminating the need for complex fixtures to machine and inspect perimeter weld beads while maintaining secure attachment.
2Manufacturing precision
If multiple perimeter weld beads are machined, then precise dimensions are achieved, but manufacturing time and costs increase
Solution Approach 1:
The patent removes the machining operation entirely by eliminating the perimeter weld bead design. The retainer features pre-formed slots and structures that directly accommodate bristles at the required precision, eliminating multi-step welding and machining processes.
Solution Approach 2:
The retainer is pre-formed with precisely positioned slots and features during manufacturing, before bristle insertion. This preliminary precision engineering of the retainer eliminates the need for subsequent machining operations on weld beads, maintaining dimensional precision while accelerating production.
3Reliability
If heat treatment is applied to counteract heat affected zone, then material properties are restored, but additional process steps and costs are incurred
Solution Approach 1:
The patent eliminates the source of the heat affected zone by removing the perimeter weld bead entirely. Without welding, there is no heat affected zone requiring heat treatment, thus eliminating this additional process step and reducing overall process complexity.
4Manufacturing precision
If fixtures are used for bristle hoop and subassembly machining, then accurate assembly is achieved, but fixture costs increase
Solution Approach 1:
The patent eliminates the need for expensive machining fixtures by removing the perimeter weld bead and associated machining operations. The retainer is designed with self-aligning features and pre-formed slots that guide bristle insertion without requiring complex fixture systems.
Solution Approach 2:
The retainer structure incorporates self-aligning features and pre-formed receiving structures that automatically position bristles correctly during insertion. This self-service design eliminates the need for external fixtures to maintain assembly accuracy, reducing manufacturing costs.
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 approach reduces manufacturing costs by eliminating the need for machining and perimeter welds, while maintaining a secure attachment of the bristle assembly and plates, thus providing a more cost-effective solution for brush seal assembly production.
Implementation Method 1
A circumference of the subassembly is pressed into a retaining ring to provide the brush seal assembly
Data Source
AI summary
A brush seal assembly is disclosed that includes bristles arranged circumferentially about an axis to provide a bristle assembly. First and second plates are secured about the bristle assembly to provide a subassembly. A circumference of the subassembly is pressed into a retaining ring to provide the brush seal assembly. The circumference need not be machined. A perimeter weld is no longer needed to secure the first and second plates and bristle assembly to one another to provide the brush seal assembly.