Composite Fuel Spray Bar Structure With Seamless Multi-Lumen Manifolds
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Solution Overview
Problem
Traditional manufacturing methods for fuel manifolds in gas turbine engines require numerous individual machined components, leading to complex, expensive, and impractical assemblies with many joints, which are difficult to produce and service, and often necessitate replacing the entire assembly if any part is faulty.
Innovation Solution
The development of seamless, unitary, multi-lumen fuel distribution components formed through additive manufacturing, creating a single-piece structure with complex internal geometries that were previously impossible to produce using traditional methods, reducing the number of joints and enhancing serviceability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional manufacturing methods are used to assemble multiple machined components, then the fuel manifold can be produced with conventional techniques, but the assembly becomes extremely complicated, expensive, and difficult to service
Solution Approach 1:
The patent merges multiple separate machined components into a single monolithic fuel manifold structure. This eliminates the need for assembling dozens of individual components and joints, directly resolving the contradiction by reducing assembly complexity while maintaining manufacturability through advanced fabrication techniques
Solution Approach 2:
The patent segments the fuel manifold into multiple functional lumens (fuel supply, return, cooling channels) within a single monolithic structure. This allows complex internal flow paths to be achieved without requiring multiple external components, resolving the contradiction between manufacturability and assembly complexity
2Ease of manufacture
If multiple individual components are assembled to form the fuel manifold, then the component can be produced using conventional machining, but the number of joints increases, making the assembly expensive and structurally complex
Solution Approach 1:
The patent combines multiple components that would traditionally be joined through welding or brazing into a single monolithic structure. This eliminates numerous joints and associated manufacturing steps, directly addressing the contradiction by reducing joint quantity while maintaining manufacturability through additive manufacturing or other advanced fabrication methods
3Ease of manufacture
If the fuel manifold assembly is made with many joints and components, then it can be produced using traditional assembly methods, but it requires extensive external bracing for support and strengthening
Solution Approach 1:
The patent merges multiple components into a single monolithic structure that inherently provides structural strength without requiring external bracing. The unified structure eliminates weak points at joints and connections, resolving the contradiction by improving structural strength while maintaining manufacturability through integrated design
Solution Approach 2:
The patent incorporates curved and optimized flow paths within the monolithic structure that naturally strengthen the geometry and improve fluid dynamics. The curved lumens and optimized pathways provide structural integrity without external support, addressing the contradiction between traditional assembly feasibility and structural strength
4Ease of manufacture
If the fuel manifold is assembled from multiple components, then it can be manufactured using conventional processes, but it becomes impractical to service and requires complete assembly replacement
Solution Approach 1:
The patent combines multiple serviceable functions (fuel supply, return, cooling) into a single monolithic manifold that can be manufactured once and serviced as a unit. This resolves the contradiction by improving serviceability through reduced complexity while maintaining conventional manufacturing processes for production
Data Source
AI summary
The subject matter of this specification can be embodied in, among other things, a fuel delivery component, a substantially rigid, unitary structure formed as a single piece of material, and at least a first seamless lumen defined by the unitary structure as a first loop.