Flexible Seal Assembly With Sintered Metal Matrix Flexure
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing flexible seal assemblies in industrial applications like gas turbines and aerospace turbines face issues with leakage, durability, temperature resistance, and wear due to high torsional rigidity and limited longitudinal flexure, leading to inefficiencies and operational challenges.
Innovation Solution
A flexible seal assembly comprising multiple layers of metal matrix sheet material made from randomly arranged thin wire segments, sintered together to form a semi-rigid sheet, encapsulated within a metal casing that provides low torsional rigidity and high longitudinal flexure, allowing for effective sealing and reduced wear during component movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional rigid seal assemblies are used, then sealing capability is provided, but wear to components increases and flexibility is reduced
Solution Approach 1:
The patent employs a flexible seal assembly constructed from metal matrix sheet material that can bend and conform to component movements. The seal assembly includes a flexible core layer made of sintered metal particles that provides sealing capability while allowing longitudinal flexure and torsional movement, eliminating the need for rigid seal structures.
Solution Approach 2:
The seal assembly uses a composite structure combining metal matrix sheet material with specific structural characteristics. The metal matrix provides durability and sealing capability, while the sintered particle structure and layered construction provide flexibility and wear resistance, creating a material that simultaneously achieves both sealing strength and operational flexibility.
2Stability of the object's composition
If previously known rigid seals are used, then structural stability is maintained, but wear issues occur and operational lifetime is reduced
Solution Approach 1:
The patent changes the physical parameters of the seal material by using sintered metal particles with controlled size distribution and porosity. The metal matrix structure provides structural stability while the controlled porosity and particle arrangement allow for wear accommodation and self-lubrication, extending operational lifetime without sacrificing stability.
Solution Approach 2:
The flexible seal assembly is designed as a replaceable component that can wear without damaging adjacent expensive turbine components. The seal assembly itself is engineered to be the sacrificial element that protects more critical components, extending the overall system operational lifetime even if the seal needs periodic replacement.
3Reliability
If traditional seals are used to fill gaps, then leakage paths are blocked, but the seals lack durability and resiliency
Solution Approach 1:
The metal matrix sheet material has a controlled porous structure resulting from the sintering process. This porous structure allows the seal to deform and conform to gap variations, maintaining sealing effectiveness, while the metal particle framework provides durability and resistance to degradation from thermal and mechanical stresses.
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 flexible seal assembly maintains a seal during component movement while reducing wear and improving operational lifetime, enhancing the sealing efficiency and durability without compromising flexibility.
Implementation Method 1
The metal matrix sheet material can be made from a plurality of segments of thin wire arranged in a random fashion to create a sheet structure, and which are then sintered together to form a semi-rigid sheet.
Data Source
AI summary
Flexible seal assemblies having a relatively low torsional rigidity and high longitudinal flexure to thereby allow the flexible seal assembly to flex between adjacent components and maintain a seal, even when movement between adjacent components occurs, is described. In some embodiments, the flexible seal assembly includes one or more layers of metal matrix material, the metal matrix material being comprised of a plurality of short segments of thin wire arranged randomly and sintered together to form a semi-rigid sheet. The one or more layers of metal matrix material can be sandwiched between an upper casing and a lower casing of a metal alloy casing. In various embodiments, additional features are provided for helping to make sure the seal assembly stays together, such as spot welds formed through the seal assembly, an S-shaped casing, and a recess/protrusion feature provided on adjacent layers of metal matrix material.