Flexible Ceramic Matrix Composite Seal for Gas Turbine Tolerance

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Solution Overview

Problem

Current ceramic matrix composite seals in gas turbine engines face challenges in maintaining effective sealing due to manufacturing tolerances and thermal expansion, leading to misalignment of groove recesses and leakage issues, especially at high temperatures.

Innovation Solution

A ceramic matrix composite seal design incorporating multiple ceramic fiber fabrics embedded in a ceramic matrix, with specific geometric configurations and reinforcement structures, allowing for flexibility and improved alignment within varying groove tolerances, and featuring a depression in the first fiber assembly and a corresponding depression in the second fiber assembly to enhance sealing performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a rigid ceramic matrix composite seal is used, then high temperature resistance is improved, but adaptability to groove tolerance variations deteriorates

Engineering Contradiction:

Improvehigh temperature resistanceVSAvoidadaptability to groove tolerance

Core Design Contradiction:

TemperatureVSAdaptability or versatility

Solution Approach 1:

The seal transitions from a rigid structure to a flexible one by incorporating through-going reinforcement fibers that allow controlled deformation. The flexible reinforcement structure enables the seal to dynamically adapt its shape to accommodate groove misalignment while maintaining structural integrity at high temperatures.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The invention changes the mechanical parameters of the ceramic matrix composite by introducing flexible reinforcement phases. This creates a composite material that exhibits both high-temperature stability and flexibility, allowing the seal to deform elastically and plastically to match groove variations.

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If the seal deforms plastically to accommodate misalignment, then adaptability is improved, but structural stability deteriorates

Engineering Contradiction:

Improvealignment accommodationVSAvoidstructural stability

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The invention uses a composite structure combining a ceramic matrix with flexible reinforcement fibers. The ceramic matrix provides high-temperature stability and structural integrity, while the flexible reinforcement allows controlled plastic deformation. This composite approach enables the seal to accommodate misalignment without compromising overall structural stability.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The flexible reinforcement structure is designed to absorb misalignment stresses through controlled plastic deformation before they can compromise the ceramic matrix structure. This pre-planned deformation capacity cushions the system against the harmful effects of groove misalignment.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Reliability

If multiple fiber assemblies with complex geometry are used, then sealing performance is improved, but device complexity increases

Engineering Contradiction:

Improvesealing performanceVSAvoidfiber assembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The seal is divided into multiple fiber assemblies, each containing multiple fabric layers with specific orientations. This segmentation allows each layer to contribute specific functional properties (flexibility, strength, deformation capacity) while collectively achieving superior sealing performance across varying groove conditions.

Inventive Principle:

Principle #1Segmentation

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 provides improved sealing performance across a broader range of groove or gap tolerances, maintains contact with components under thermal expansion, and achieves infinite life in compression cycles by deforming plastically and storing potential energy for expansion, ensuring effective sealing in high-temperature applications.

Implementation Method 1

achieves infinite life in compression cycles by deforming plastically and storing potential energy for expansion

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Implementation Method 2

maintains contact with components under thermal expansion

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentEP2969554B1Flexible ceramic matrix composite seal assembled with gas turbine engine components

Publication Date: 2019.05.08 ROLLS ROYCE CORP

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AI summary

A ceramic matrix composite seal is disclosed. The ceramic matrix composite seal including a ceramic matrix and a number of ceramic fiber fabrics embedded in the ceramic matrix. The ceramic matrix composite seal is formed into a strip with a desired geometry such that the seal strip is configured to be assembled with a number of components to create a seal between the components.