Ceramic Panel Airfoil for Gas Turbine Engine Cooling
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Solution Overview
Problem
Gas turbine engines face efficiency challenges due to the need for compressor bleed cooling, which penalizes engine efficiency by relying on pressure differential, making it difficult to lower volume, increase velocity, and increase temperature of compressor bleed simultaneously.
Innovation Solution
The airfoil design incorporates ceramic panels and a metal core structure with interlocking connectors and a geometrically segmented coating, enhancing thermal resistance and reducing the need for compressor bleed cooling by providing internal passages and film cooling, and using a segmented coating to manage thermal stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If compressor bleed cooling is used to cool turbine components, then temperature resistance is improved, but engine efficiency deteriorates due to pressure differential requirements
Solution Approach 1:
The patent changes the material parameter of turbine components from traditional metal to ceramic materials, which inherently possess higher temperature resistance. This allows the components to withstand higher temperatures without requiring compressor bleed cooling, thereby eliminating the efficiency penalty associated with pressure differential requirements for cooling
Solution Approach 2:
The patent employs ceramic matrix composite (CMC) materials that combine the high temperature resistance of ceramics with the structural integrity needed for turbine components. These composite materials enable operation at elevated temperatures without the need for extensive cooling systems that would reduce engine efficiency
2Temperature
If ceramic panels are used to enhance temperature resistance, then thermal resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent divides the turbine component into discrete ceramic panels that can be manufactured separately and then assembled together. This segmentation allows for simplified manufacturing of individual panels compared to creating large monolithic ceramic components, reducing overall manufacturing complexity while maintaining temperature resistance
Solution Approach 2:
The patent integrates cooling passages and structural features within the ceramic panels themselves, nesting multiple functions into single components. This reduces the number of separate parts and assembly steps required, thereby decreasing manufacturing complexity despite the use of advanced ceramic materials
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 design enhances the temperature resistance of turbine components, reducing the need for compressor bleed cooling and improving engine efficiency by allowing higher temperature operation without efficiency penalties.
Implementation Method 1
The geometrically segmented coating section includes a wall that has an outer side. The outer side includes an array of cells, and a coating is disposed in the array of cells.
Implementation Method 2
The panel is ceramic and the core structure is metal.
Implementation Method 3
The panel includes an internal passage, an external wall that borders the internal passage, and a cooling hole that extends through the external wall and that opens to the internal passage.
Data Source
Figure 1~2B
Figure 2A~6
Figure 3~4
AI summary
An airfoil (60) includes an airfoil section (66) that defines an airfoil profile (AP). The airfoil section (66) includes a panel (70) that forms a portion of the airfoil profile (AP) and a core structure (72) to which the panel (70) is secured.