Monolithic Diffuser Ring Air Manifold for Aircraft Engine
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Solution Overview
Problem
Existing secondary air systems in aircraft engines face challenges with cumbersome, heavy, and difficult-to-seal fluid lines that connect components, leading to potential leakage and inefficiencies.
Innovation Solution
The design incorporates a diffuser ring and air manifold as a single monolithic body, with apertures and inlets that direct compressed air from the compressor section to a bearing housing, eliminating the need for external air lines by integrating the air path within the engine casing, thereby reducing weight, pressure drops, and leakage risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional fluid lines are used to connect secondary air system components, then the system can be assembled from separate parts, but the system becomes heavy, cumbersome to install, and difficult to seal against leakage
Solution Approach 1:
The patent integrates the air manifold and diffuser ring into a single monolithic component formed from one piece of material. This merging eliminates the need for separate fluid lines to connect the air supply to the bearing housing, thereby reducing weight while maintaining manufacturability through single-piece fabrication processes
2Adaptability or versatility
If traditional fluid lines are used to connect secondary air system components, then the system can be modular, but the fluid lines are heavy and difficult to seal
Solution Approach 1:
By combining the air manifold and diffuser ring into a single monolithic structure, the patent eliminates multiple connection interfaces that would require sealing. The integrated design removes joints and seams where leaks could occur, thereby improving reliability while maintaining the adaptability of the secondary air system configuration
3Ease of operation
If separate air lines are used to deliver compressed air to bearing housing, then the system is easier to assemble, but the air lines add weight and potential leakage points
Solution Approach 1:
The patent integrates the air delivery function directly into the diffuser ring structure, eliminating separate air lines. The monolithic design incorporates internal passages that route compressed air from the compressor section to the bearing housing, reducing weight while maintaining ease of assembly as a single component
4Ease of manufacture
If multiple separate components are used in the secondary air system, then the system is easier to manufacture, but the part count increases leading to more leakage risks and higher costs
Solution Approach 1:
The patent combines the air manifold and diffuser ring into a single monolithic component, reducing the part count from multiple separate parts to one integrated component. This integration maintains manufacturability through single-piece fabrication while eliminating the complexity of assembling and sealing multiple joints, thereby reducing leakage risks and manufacturing costs
Data Source
AI summary
An aircraft engine has: a compressor section having a compressor rotor rotatable about a central axis; a diffuser downstream of the compressor rotor, the diffuser including a diffuser ring extending circumferentially around the central axis; a bearing housing secured to the diffuser ring, the bearing housing contained within a volume located radially inwardly of the diffuser ring; and an air manifold secured to the diffuser ring, the air manifold defining inlets in fluid flow communication with the compressor section and an outlet in fluid flow communication with the volume.