Radial Compressor Baffle Geometry for Interstage Leakage Control

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Solution Overview

Problem

Multistage radial compressors experience efficiency loss due to interstage leakage and increased gas temperature, which diminishes the effectiveness of the second stage compression.

Innovation Solution

A baffle is designed with complementary shapes to the compressor wheels, featuring a tip portion that promotes vortex formation and reduces interstage leakage by guiding gas flow from high to low pressure regions, while accounting for thermal expansion and maintaining optimal spatial relationships across varying temperatures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a conventional baffle design is used in multistage radial compressors, then the structure is simple, but interstage leakage increases and compression efficiency decreases

Engineering Contradiction:

Improvecompression efficiencyVSAvoidbaffle structure complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The baffle incorporates curved surfaces and rounded transitions instead of sharp angles, creating smooth flow paths that reduce turbulence and enhance vortex formation. The curved geometry optimizes gas flow patterns between compressor stages, minimizing leakage while maintaining structural integrity.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

Different portions of the baffle have specialized geometries tailored to local flow requirements. The leading edge features specific curvature radii for vortex generation, while trailing portions have different profiles for flow control, optimizing performance at each location rather than using a uniform design.

Inventive Principle:

Principle #3Local quality

2Productivity

If the baffle is positioned to minimize interstage leakage, then compression efficiency improves, but thermal expansion at operating temperatures may cause contact with rotating components

Engineering Contradiction:

Improvecompression efficiencyVSAvoidclearance maintenance at operating temperature

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The baffle design explicitly accounts for thermal expansion by incorporating expansion clearances and positioning features. The geometry includes designated gaps and flexible mounting arrangements that accommodate dimensional changes at operating temperatures, preventing contact with rotating components while maintaining leakage control.

Inventive Principle:

Principle #37Thermal expansion

Solution Approach 2:

The baffle is divided into multiple sections or segments that can independently accommodate thermal expansion. This segmentation allows different portions of the baffle to expand differently based on local temperature gradients, maintaining overall clearance requirements without compromising the sealing function.

Inventive Principle:

Principle #1Segmentation

3Productivity

If the baffle geometry is optimized for vortex formation, then interstage leakage is reduced, but manufacturing precision requirements increase

Engineering Contradiction:

Improveleakage reductionVSAvoidgeometric tolerance

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The use of curved surfaces with specified radius ranges provides manufacturing tolerance buffering. Rather than requiring precise angular measurements, the curved geometry allows for easier fabrication while maintaining the vortex-generating flow patterns, reducing the stringency of tolerance requirements.

Inventive Principle:

Principle #14Spheroidality (Curvature)

4Productivity

If the baffle extends further into the compression chamber to block leakage paths, then interstage leakage decreases, but the risk of contact with rotating wheels increases

Engineering Contradiction:

Improveleakage controlVSAvoidcontact risk with rotating components

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The extended baffle geometry incorporates thermal expansion clearances that maintain safe distances from rotating wheels even when the baffle extends further into the compression chamber. The design anticipates thermal growth and positions the extended portions to avoid contact under operating conditions.

Inventive Principle:

Principle #37Thermal expansion

Solution Approach 2:

The extended portions of the baffle use curved leading edges that guide flow smoothly rather than creating sharp discontinuities. This curvature allows the baffle to extend closer to rotating components while maintaining safe clearance through the rounded geometry, reducing the risk of contact while still blocking leakage paths.

Inventive Principle:

Principle #14Spheroidality (Curvature)

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 baffle effectively minimizes interstage leakage and maintains efficiency by promoting vortex formation, thereby enhancing the overall performance of the two-stage compressor assembly.

Implementation Method 1

a tip portion 381 that promotes vortex formation with a maximum Mach number

Methodology Applied

Scientific EffectVortex formation: Vortex Ring

Implementation Method 2

guiding gas flow from high to low pressure regions

Methodology Applied

Scientific EffectPressure gradient flow: Pressure Gradient

Implementation Method 3

accounting for thermal expansion and maintaining optimal spatial relationships across varying temperatures

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS12516670B2Multistage radial compressor baffle

Publication Date: 2026.01.06 GARRETT TRANSPORTATION I INC

AI summary

An assembly can include a first radial compressor wheel that has a rotational axis and that includes a hub surface; a second radial compressor wheel that comprises a hub surface; and an annular baffle disposed at least in part between the hub surfaces wherein the annular baffle an outer edge and a substantially parabolic portion that extends to a tip portion, where the tip portion includes opposing sides that converge radially inwardly to a blunt end.