Flexible Insert Seals Collector-Manifold Interface in Aircraft Engine

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Solution Overview

Problem

Active clearance control systems in gas turbine engines face leakage issues due to movement or deflection of collector components, leading to a potential loss of closure and reduced system performance.

Innovation Solution

An insert with a flange and posts/chimneys is coupled to the collector and manifolds, providing a seal and accommodating relative movement to prevent leaks and ensure adequate sealing across the engine's operating range.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the collector is rigidly connected to the manifolds, then the sealing is improved, but the system cannot accommodate thermal expansion and vibratory loads

Engineering Contradiction:

ImprovesealingVSAvoidaccommodation of movement

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent employs flexible sealing elements including an elastomeric gasket and flexible lips that can deform to maintain sealing while accommodating relative movement between the collector and manifolds. The flexible gasket is compressed between the collector flange and manifold surface, allowing it to conform to movements and maintain contact.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The sealing system is designed to be dynamic rather than static, allowing the sealing elements to move and deform with the collector and manifolds during thermal expansion and vibration. The flexible lips and gasket maintain continuous contact despite relative displacement, adapting to changing geometry.

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If the collector moves or deflects during operation, then thermal expansion and load accommodation are improved, but leakage occurs at the interface

Engineering Contradiction:

Improveaccommodation of thermal loadsVSAvoidsealing

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The elastomeric gasket and flexible sealing lips can deform elastically to maintain sealing contact during thermal expansion and vibratory movement. The material flexibility allows the seal to conform to changing interface geometry without losing contact.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The sealing design anticipates movement by providing a compliant sealing layer that absorbs displacement before leakage can occur. The flexible gasket acts as a cushion that accommodates expected thermal and vibratory movements while maintaining sealing integrity.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Ease of manufacture

If a traditional rigid sealing method is used, then manufacturing simplicity is improved, but the system cannot maintain closure under operational loads

Engineering Contradiction:

Improvesealing structureVSAvoidsystem closure

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The elastomeric gasket and flexible sealing lips provide effective sealing while maintaining relatively simple manufacturing and assembly procedures. The flexible components can be installed in a straightforward manner and accommodate movement without requiring complex adjustment mechanisms.

Inventive Principle:

Principle #30Flexible shells and thin films

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 insert effectively bridges the gap between manifolds and collector, maintaining system performance by minimizing leakage and ensuring consistent closure of the active clearance control system.

Implementation Method 1

an elastomeric gasket may be compressed between a collector flange and a manifold surface

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

flexible lips extending from the insert toward the manifold may seal an interface between the insert and the manifold

Methodology Applied

Scientific EffectFlexibility: Elasticity

Implementation Method 3

The insert may accommodate relative movement between at least two of a first of the manifolds, a second of the manifolds, and the collector over an operating range of an engine

Methodology Applied

Scientific EffectMechanical deformation: Deformation

Data Source

PatentEP3757353B1Insert for a collector of an active clearance control system of an engine of an aircraft

Publication Date: 2023.05.10 RTX CORP

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AI summary

Aspects of the disclosure are directed to an active clearance control system (300) for an engine of an aircraft, comprising: a collector (318) that is configured to receive a cooling fluid (304), at least two manifolds (312a, b) coupled to the collector (318), where a first of the manifolds (312a) is configured to receive at least a first portion of the cooling fluid (304) from the collector (318) and a second of the manifolds (312b) is configured to receive at least a second portion of the cooling fluid (304) from the collector (318), and an insert (330) coupled to the collector (318) and the manifolds (312a, b), where the insert (330) is configured to seal an interface between the collector (318) and the at least two manifolds (312a, b) over an operating range of the engine.