Fiber-Reinforced Engine Inlet Compression Seal With Pressurized Bulb
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Solution Overview
Problem
The existing compression seals in gas turbine engines, particularly those used in military aircraft, face challenges with manufacturing difficulties and susceptibility to cycle fatigue, especially the J-seal made of titanium, which is difficult to manufacture and prone to fatigue.
Innovation Solution
A non-metallic engine case inlet compression seal is designed with a non-metallic arcuate interface section, longitudinal leg section, and mount flange section, where each section can have a different durometer and may be made of silicone rubber with fiber reinforcement, forming a circular 'J' seal, and incorporating features like apertures and pressurized bulbs to enhance sealing and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a titanium J-seal is used for the engine case inlet compression seal, then the seal provides effective sealing and structural strength, but the seal is difficult to manufacture and susceptible to cycle fatigue
Solution Approach 1:
The patent changes the material parameters by transitioning from titanium to non-metallic materials (such as graphite or composite materials). This parameter change enables easier manufacturing through methods like molding or machining, while maintaining sealing effectiveness and structural strength through the inherent properties of the non-metallic materials and optimized geometric design of the seal sections.
Solution Approach 2:
The patent employs composite material construction for the J-seal, combining different materials with complementary properties. The seal integrates a non-metallic body material (such as graphite) with reinforcing elements or coating layers, creating a composite structure that achieves both ease of manufacture and high reliability, while resisting cycle fatigue through the material combination.
2Strength
If a titanium J-seal is used for the engine case inlet compression seal, then the seal provides structural strength, but the seal is susceptible to cycle fatigue
Solution Approach 1:
The patent changes the material parameters by replacing titanium with non-metallic materials that have superior fatigue resistance characteristics. The non-metallic materials (such as graphite or composite materials) exhibit better resistance to cyclic loading and thermal fatigue, thereby improving reliability under repeated engine operation cycles while maintaining adequate structural strength.
Solution Approach 2:
The patent uses composite material construction to achieve both structural strength and fatigue resistance. The composite structure combines a non-metallic base material with reinforcing elements, creating a seal that maintains structural integrity under load while resisting cycle fatigue through the synergistic properties of the composite materials.
3Adaptability or versatility
If different durometer sections are used in the non-metallic seal, then the seal offers design flexibility and improved sealing, but the manufacturing complexity increases
Solution Approach 1:
The patent applies local quality by varying the durometer (hardness) of different sections of the J-seal to optimize performance in specific locations. The arcuate interface section, longitudinal leg section, and mount flange section can have different durometer values tailored to their functional requirements, such as softer sections for sealing contact and harder sections for structural support, thereby achieving design flexibility and improved sealing effectiveness.
Solution Approach 2:
The patent uses composite material construction to achieve different durometer sections within a single integrated seal component. By combining materials with different hardness properties or using gradient material structures, the seal achieves varied local properties without requiring multiple separate parts, thus managing manufacturing complexity while maintaining design flexibility.
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 non-metallic seal is easier to manufacture, provides improved durability and resistance to cycle fatigue, and offers design flexibility with varying stiffness and reinforcement, ensuring effective sealing and reduced sensitivity to handling conditions.
Implementation Method 1
the non-metallic arcuate interface section forms a bulb; and an interface to the bulb to receive air to pressurize the bulb
Data Source
AI summary
A non-metallic engine case inlet compression seal for a gas turbine engine includes a non-metallic longitudinal leg section that extends from the non-metallic arcuate interface section and a non-metallic mount flange section that extends from the longitudinal leg section.