3D Diffuser Scoop Fuel Injector for Low-Loss Combustor Mixing

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Solution Overview

Problem

Existing fuel injectors and air flow paths in combustor liners of turbine engines require improvement to enhance fuel-air mixing and reduce pressure losses for improved combustion efficiency.

Innovation Solution

A combustor system with integrated air scoops and splash plates that direct air and fuel into a central combustor chamber, utilizing fluid dynamics to improve airflow and fuel mixing, and incorporating additively manufactured components for tighter clearances and higher efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional fuel injectors and air flow paths are used in combustor liners, then the structure is simpler and manufacturing is easier, but fuel-air mixing is insufficient and pressure losses are higher

Engineering Contradiction:

Improvecombustion efficiencyVSAvoidflow path structure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The diffuser is segmented into multiple radial sections (first radial section, second radial section, third radial section) with different curvature radii. Each section creates specific flow patterns that enhance fuel-air mixing. The segmentation allows optimization of airflow characteristics in different zones while maintaining overall system functionality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different radial sections of the diffuser have locally optimized curvature radii to achieve specific flow control objectives. The first radial section has a larger curvature radius for gentle flow guidance, while the second and third sections have smaller curvature radii to create controlled turbulence and enhance mixing in specific regions where fuel injection occurs.

Inventive Principle:

Principle #3Local quality

2Productivity

If tighter clearances are implemented in diffuser components, then combustion efficiency improves, but manufacturing precision requirements increase

Engineering Contradiction:

Improvecombustion efficiencyVSAvoidclearance tolerance

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The curvature radius parameter is varied across different radial sections of the diffuser. By changing the geometric parameter (curvature radius) locally in different sections, the design achieves tighter effective clearances and improved flow control without requiring uniform high-precision manufacturing throughout the entire component. Each section's curvature radius is optimized for its specific functional requirement.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If integrated air scoops and splash plates are added to direct air and fuel, then fuel-air mixing is enhanced, but device complexity increases

Engineering Contradiction:

Improvefuel-air mixingVSAvoidinjector components

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The air scoop and fuel manifold are merged into a single integrated component. The fuel manifold is positioned within the air scoop structure, combining two functions (air direction and fuel distribution) into one component. This integration reduces the number of separate parts while achieving enhanced fuel-air mixing through the coordinated design of both functions within the unified structure.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated air scoop and fuel manifold component performs multiple functions: it directs airflow into the combustor chamber, distributes fuel through embedded orifices, and creates controlled mixing zones. This multi-functional design eliminates the need for separate air delivery and fuel injection components, reducing overall system complexity while maintaining enhanced mixing performance.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 reduces air pressure losses, enhances fuel-air mixing, and improves combustion efficiency with lower smoke emissions, while allowing for higher efficiency and reduced part costs through additive manufacturing.

Implementation Method 1

utilizing fluid dynamics to improve airflow and fuel mixing

Methodology Applied

Scientific EffectFluid dynamics:

Implementation Method 2

enhances fuel-air mixing

Methodology Applied

Scientific EffectFuel-air mixing:

Implementation Method 3

reduces air pressure losses

Methodology Applied

Scientific EffectPressure losses reduction:

Data Source

PatentUS12516816B13D diffuser fed scoop fuel injector

Publication Date: 2026.01.06 RTX CORP

AI summary

A combustor system for an aerial vehicle includes an diffuser case with a first and second end and a large and small radius section, an inner diffuser wall contained within the diffuser case, the inner diffuser wall with a lumen, a central combustor chamber, a first air flow path extending between the diffuser case and inner diffuser wall, an integrated air scoop attached to the inner diffuser wall at the first lumen that directs air from the first air flow path into the central combustor chamber, a fuel manifold and fuel orifice within the integrated air scoop, and a splash plate comprising with a first and second face. The splash plate extends through the lumen into the central combustor chamber. The large radius section is aligned with the inner diffuser wall away from the splash plate and the small radius section is aligned with the splash plate.