Multi-Passage Fuel Injector Assembly for Hydrogen Flashback Control

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Solution Overview

Problem

The transition to hydrogen fuel in turbine engines poses challenges due to high flame speeds and reaction rates, leading to flashback and potential damage from flame attachment on gas fuel swirl vanes.

Innovation Solution

A fuel injector nozzle assembly with multiple fluid passages and swirler configurations is designed to manage hydrogen use, incorporating inner and outer housing bodies and a float swirler to impart swirls to different fluids, ensuring stable combustion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If hydrogen is used as fuel in turbine engines, then fuel efficiency and emissions are improved, but flashback and flame attachment damage occur due to high flame speeds and reaction rates

Engineering Contradiction:

Improvefuel efficiencyVSAvoidflashback and flame attachment damage

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The combustor is divided into multiple zones with different swirl vanes (inner swirl vanes, outer swirl vanes, and float swirler) that segment the fuel flow paths. This segmentation allows different regions to handle hydrogen at different swirl intensities, preventing flashback in high-speed regions while maintaining stable combustion in controlled regions.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The float swirler acts as an intermediary component between the inner and outer swirl vanes, providing an additional layer of flow control. The float mechanism mediates the interaction between combustion gases and fuel flow, stabilizing the flame front and preventing direct flame attachment to the vanes while still allowing efficient hydrogen combustion.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-generated harmful factors

If high levels of hydrogen (up to 100%) are mixed with methane, then emissions are reduced, but flame attachment damage occurs on gas fuel swirl vanes

Engineering Contradiction:

ImproveemissionsVSAvoidflame attachment damage

Core Design Contradiction:

Object-generated harmful factorsVSObject-affected harmful factors

Solution Approach 1:

Different regions of the combustor are given different local qualities through the use of inner swirl vanes, outer swirl vanes, and float swirler. The inner regions handle high hydrogen content mixtures with controlled swirl, while outer regions provide additional stabilization. This local differentiation allows 100% hydrogen operation without flame attachment damage to any single component.

Inventive Principle:

Principle #3Local quality

3Device complexity

If conventional fuel injectors are used with hydrogen, then system simplicity is maintained, but stable combustion cannot be achieved due to high flame speeds

Engineering Contradiction:

Improvesystem simplicityVSAvoidcombustion stability

Core Design Contradiction:

Device complexityVSStability of the object's composition

Solution Approach 1:

The patent merges multiple swirl control mechanisms (inner swirl vanes, outer swirl vanes, and float swirler) into a single integrated fuel injector assembly. This combination provides the complex flow control needed for stable hydrogen combustion while maintaining a relatively simple overall system architecture that can be implemented as a single replaceable component.

Inventive Principle:

Principle #5Merging (Combining)

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 stabilizes hydrogen combustion, reducing flashback risks and enhancing operational safety by managing flame behavior within the nozzle assembly.

Implementation Method 1

a float swirler arranged radially outward from the outer housing body... configured to supply a third fluid, the plurality of third fluid passages include... an inner third fluid passage defined within the float swirler

Methodology Applied

Scientific EffectSwirl flow: Vortex Ring

Implementation Method 2

the center body comprises inner path vanes arranged on the interior surface thereof, the inner path vanes arranged within the inner airflow passage to impart a swirl to a fluid passing therethrough

Methodology Applied

Scientific EffectSwirl flow: Vortex Ring

Implementation Method 3

a combustor section to burn a fuel in the presence of the pressurized air

Methodology Applied

Scientific EffectCombustion: Combustion

Data Source

PatentUS12584630B2Fuel injector assembly for turbine engines

Publication Date: 2026.03.24 RTX CORP

AI summary

Fuel injector nozzle assemblies for turbine engines include an inner housing body having a center body installed within the inner housing, an intermediate housing body arranged around the inner housing, an outer housing body arranged around the intermediate housing, and a float swirler arranged around the outer housing body. The center body is a hollow body structure. A first passage partially defined between the inner housing and the intermediate housing is configured to supply a first fluid and a second passage partially defined between the intermediate housing and the outer housing is configured to supply a second fluid. A plurality of third passages are configured to supply a third fluid and include a center third passage defined within the center body, an inner third passage within the float swirler, and an outer fluid passage defined within the float swirler and radially outward from the inner third fluid passage.