Carbon Face Seal Geometry to Limit Dynamic Seal Instability

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Solution Overview

Problem

Carbon face seals in gas turbine engines are prone to dynamic instability, leading to coupled radial and axial displacements that result in leaks, rapid wear, and premature failure due to excessive stresses beyond the capability of the spring element.

Innovation Solution

The solution involves a radial gap formed between the outer diameter surface of the seal and the inner diameter surface of the seat, with specific geometric features such as a chamfer surface and axial undercut, which help to limit dynamic radial excursions and prevent axial separation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the carbon seal is axially spring biased into engagement with the seat to maintain sealing contact, then sealing effectiveness is improved, but dynamic instability leading to coupled axial and radial displacements causes premature failure

Engineering Contradiction:
Improvesealing effectivenessVSAvoidseal service life
Core Design Contradiction:
ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The invention introduces a radial dimension constraint by providing a radial stop surface that limits radial displacement of the seal. This adds a radial constraint dimension to the existing axial spring bias, creating a two-dimensional constraint system that prevents the coupled radial-axial dynamic instability while maintaining axial sealing contact.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The radial stop surface acts as an intermediary element between the seal and the seat structure. It mediates the radial displacement by providing a physical barrier that limits radial movement without interfering with the axial spring bias mechanism, thereby decoupling the radial and axial motion constraints.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Adaptability or versatility

If the seal is allowed radial movement to accommodate dynamic conditions, then adaptability is improved, but coupled radial and axial displacements lead to leaks and rapid wear

Engineering Contradiction:
Improvedynamic accommodationVSAvoidsealing integrity
Core Design Contradiction:
Adaptability or versatilityVSReliability

Solution Approach 1:

The radial stop surface introduces a radial constraint dimension that works alongside the axial spring bias. This creates a controlled two-dimensional movement envelope that allows necessary radial accommodation while preventing the excessive coupled displacements that lead to sealing failures.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The invention changes the displacement parameters by limiting the radial displacement magnitude through the radial stop surface. This parameter control ensures that radial movements remain within acceptable bounds that prevent coupled axial displacements and maintain sealing integrity under dynamic conditions.

Inventive Principle:
Principle #35Parameter changes

3Strength

If the spring element is designed to handle high stresses from dynamic instability, then durability is improved, but the spring element still fails under extreme coupled displacements

Engineering Contradiction:
Improvespring element capacityVSAvoidseal system stability
Core Design Contradiction:
StrengthVSReliability

Solution Approach 1:

The radial stop surface provides preliminary anti-action by preventing the radial displacement that would lead to coupled axial displacements. This preemptive constraint stops the instability mechanism before it can generate excessive stresses that would overwhelm the spring element's capacity.

Inventive Principle:
Principle #9Preliminary anti-action

Solution Approach 2:

The radial stop surface acts as a protective constraint that cushions against the development of dynamic instability. By limiting radial movement in advance, it prevents the chain of events that would lead to coupled displacements and spring element failure, effectively cushioning the system against premature failure.

Inventive Principle:
Principle #11Beforehand cushioning (Prior cushioning)

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 effectively limits coupled dynamic displacements, preventing leaks and reducing wear and stress on the seal, thereby extending its operational life and maintaining the structural integrity of the gas turbine engine.

Implementation Method 1

The seal is mounted to a first structure and biased into engagement with a seat by a bellows spring

Methodology Applied
Scientific EffectElasticity: Elasticity

Implementation Method 2

The sliding engagement causes frictional heating. The heat must be dissipated.

Methodology Applied
Scientific EffectFriction: Friction

Implementation Method 3

oil cooled carbon seals are divided into two categories: 'dry face' seals wherein the oil passes through passageways in the seat without encountering the interface between seal face and seat face; and 'wet face' seals wherein the oil passes through the seat to the interface so that the oil that flows through the seat cools the seat

Methodology Applied
Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 4

oil cooled carbon seals are divided into two categories: 'dry face' seals wherein the oil passes through passageways in the seat without encountering the interface between seal face and seat face

Methodology Applied
Scientific EffectConvection: Convection

Data Source

PatentEP4060209B1Self-guiding carbon seal system
Publication Date: 2025.04.09 RTX CORP
  • EP4060209B1 patent drawingFigure 1
  • EP4060209B1 patent drawingFigure 1A
  • EP4060209B1 patent drawingFigure 2

AI summary

An apparatus has a first member (36), a shaft (40, 50) rotatable relative to the first member (36) about an axis (A), and a seal system (100). The seal system (100) has: a seal (102) carried by the first member (36) and having a seal face (106); and a seat (104) carried by the shaft (40, 50) and having a seat face (108) in sliding sealing engagement with the seal face (106). The seal system (100) is a dry face seal system. The seat (104) further includes a seat section (210) having: an outer diameter surface (216) encircled by the seal (102); and a rim (212).