Brush Seal Assembly for Tight Engine Core Spaces Without Welding
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Solution Overview
Problem
Conventional brush seal manufacturing techniques become ineffective and compromise structural integrity when dimensions decrease, making it difficult to machine and seal small areas in aircraft engine cores.
Innovation Solution
A method involving a compressible core and backing with a weld-free manufacturing process, where wires are wound around cores and spacers to form a brush seal, which can be customized to fit tight spaces by cutting to specific dimensions, and includes a support structure to maintain integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional welding techniques (TIG, EBW) are used to manufacture brush seals, then structural integrity is maintained, but manufacturing complexity and difficulty increase for small dimensions
Solution Approach 1:
The brush seal is divided into multiple discrete components: a support structure, multiple bristles, and a retaining structure. These segments are assembled together without welding, allowing each component to be manufactured separately and then combined through mechanical assembly, which greatly simplifies the manufacturing process for small dimensions
Solution Approach 2:
The support structure, bristles, and retaining structure are combined into a single integrated brush seal assembly that functions as one unit. This merging allows the seal to achieve the required structural integrity through the combined action of its components rather than requiring welding of individual parts
2Adaptability or versatility
If brush seal dimensions are reduced to fit small engine areas, then adaptability to tight spaces improves, but structural integrity is compromised
Solution Approach 1:
By segmenting the brush seal into a support structure, multiple bristles, and a retaining structure, each component can be optimized for its specific function. The support structure provides mechanical strength, the bristles provide sealing functionality, and the retaining structure maintains assembly integrity, allowing the overall seal to be small while maintaining structural integrity
Solution Approach 2:
The brush seal uses a composite construction with different materials optimized for specific functions: the support structure is made from a first material, the bristles from a second material, and the retaining structure from a third material. This composite approach allows each component to contribute its optimal properties to the overall seal performance and structural integrity
3Reliability
If conventional brush seal manufacturing is used, then sealing function is achieved, but manufacturing time and complexity increase
Solution Approach 1:
The segmented design allows components to be manufactured independently and assembled quickly, eliminating time-consuming welding operations. The discrete nature of the segments enables parallel manufacturing of components and simplifies quality control, thereby improving productivity while maintaining sealing reliability
Solution Approach 2:
The bristles are configured to automatically provide the sealing function through their physical arrangement and elastic properties, without requiring additional active components or complex manufacturing processes. The retaining structure self-secures the bristles in position, eliminating the need for welding or other permanent joining methods
Data Source
Figure 1
Figure 2A~2B
Figure 2C~2D
AI summary
Aspects of the disclosure are directed to a brush seal assembly (268, 268'), comprising a compressible core (204a), at least one wire (232) wound around the core (204a), and a backing plate (254) that is substantially 'c' shaped or 'u' shaped that at least partially encases the at least one wire (232). Aspects of the disclosure are directed to a method comprising separating compressible cores (204a, b) with a spacer (210), winding wires (232) around the cores (204a, b) and the spacer (210), and forming substantially 'c' shaped or 'u' shaped backings (254) about the wires (232) to obtain a package of brush seal assemblies (268, 268').