CMC Combustor Liner With Void Pattern Cooling Channels

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Solution Overview

Problem

Implementing ceramic matrix composite (CMC) materials in gas turbine combustors poses unique challenges due to their high temperature resistance and the need for effective cooling to manage thermal gradients.

Innovation Solution

A combustor design featuring a liner with a lay-up of CMC plies, including a first and second CMC ply on either side, and intermediate CMC plies with a pattern of voids that define cooling channels, providing a three-dimensional cooling network.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If CMC materials are used in combustor liners to exploit high temperature resistance, then temperature capability is improved, but thermal gradient management becomes challenging

Engineering Contradiction:

Improvetemperature capabilityVSAvoidcooling system complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent incorporates a pattern of voids within the CMC ply structure to create internal cooling channels. These porous pathways allow cooling air to flow through the liner, managing thermal gradients while maintaining the high temperature resistance of the CMC material. The voids are strategically positioned to optimize cooling efficiency without compromising structural integrity.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent uses a multi-ply CMC composite structure where intermediate plies contain embedded voids that form cooling channels. This composite architecture combines the thermal resistance benefits of CMC materials with integrated cooling functionality, resolving the contradiction between temperature capability and thermal management complexity.

Inventive Principle:

Principle #40Composite materials

2Reliability

If intermediate CMC plies with voids are added to create cooling channels, then cooling efficiency is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvecooling efficiencyVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The cooling channels are formed by incorporating voids into the intermediate CMC plies during the lay-up process before final consolidation. This preliminary structuring of void patterns allows cooling pathways to be built-in during manufacturing rather than requiring post-processing, thereby improving cooling efficiency while managing manufacturing complexity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The void pattern is selectively positioned within specific intermediate CMC plies rather than uniformly distributed throughout the entire structure. This localized approach creates cooling channels where they are most needed for thermal management, improving cooling efficiency while minimizing the impact on overall manufacturing complexity.

Inventive Principle:

Principle #3Local quality

3Temperature

If multiple intermediate CMC plies with voids are used to form a three-dimensional cooling network, then thermal gradient management is improved, but device complexity increases

Engineering Contradiction:

Improvethermal gradient managementVSAvoidcooling network complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent extends the cooling architecture from two-dimensional surface cooling to three-dimensional internal cooling by incorporating voids in multiple intermediate CMC plies. This multi-layer void configuration creates a 3D network of cooling channels that efficiently manage thermal gradients throughout the liner thickness, transforming the cooling approach from surface-level to volumetric.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The cooling channels are nested within the intermediate CMC plies, with voids in one ply positioned to complement and connect with voids in adjacent plies. This nested arrangement creates an integrated 3D cooling network where cooling pathways are embedded within the structural layers, achieving effective thermal gradient management while maintaining a compact liner design.

Inventive Principle:

Principle #7Nested doll (Nesting)

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

The design effectively manages thermal gradients and enhances cooling efficiency within the combustor, allowing for improved performance and longevity of the gas turbine engine.

Implementation Method 1

cooling channels are bound on lateral channel sides by the at least one of the intermediate CMC plies

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 2

manages thermal gradients and enhances cooling efficiency within the combustor

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS12292193B2Combustor liner with pattern of voids in CMC fiber ply for cooling channels

Publication Date: 2025.05.06 RTX CORP

AI summary

A combustor includes a combustion chamber and a liner that bounds at least a portion of the combustion chamber. The liner includes a first side facing the combustion chamber and a second side facing away from the combustion chamber. The liner is formed of a lay-up of ceramic matrix composite (CMC) plies that have a first CMC ply on the first side, a second CMC ply on the second side, and intermediate CMC plies between the first and second CMC plies. At least one of the intermediate CMC plies has a pattern of voids that define cooling channels in the combustor panel. The cooling channels are bound on lateral channel sides by the at least one of the intermediate CMC plies.