Fuel Injector Distributor Passages with Vaulted High-Swirl Geometry

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Solution Overview

Problem

Conventional additive manufacturing techniques limit the achievable swirl angle in fluid distributors for gas turbine engine injectors, restricting design possibilities.

Innovation Solution

The fluid distributor passages are designed with a vaulted ceiling and floor in the same or opposite directions, forming a chevron or diamond cross-sectional shape, allowing swirl angles greater than 60 degrees, and are self-supported during manufacturing, enabling additive manufacturing processes to exceed conventional limits.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If conventional additive manufacturing techniques are used, then manufacturing simplicity is maintained, but the achievable swirl angle is limited

Engineering Contradiction:

Improveswirl angleVSAvoidadditive manufacturing complexity

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

The patent applies dimensionality change by transitioning from flat, planar ceiling surfaces to three-dimensional vaulted surfaces that curve along the swirl path. This allows the ceiling to follow the high swirl angle trajectory while maintaining structural integrity and self-support during additive manufacturing, effectively resolving the contradiction between achieving high swirl angles and maintaining manufacturing simplicity

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Adaptability or versatility

If high swirl angles are achieved through conventional techniques, then fluid swirl performance is improved, but design flexibility is restricted

Engineering Contradiction:

Improvedesign flexibilityVSAvoidswirl angle

Core Design Contradiction:

Adaptability or versatilityVSShape

Solution Approach 1:

The patent employs parameter changes by varying the vaulting geometry of the ceiling and floor surfaces along the swirl path. The vaulted surfaces can be configured with different radii, angles, and curvature profiles, enabling designers to optimize swirl characteristics while maintaining additive manufacturing feasibility. This provides greater design flexibility compared to conventional fixed-geometry approaches

Inventive Principle:

Principle #35Parameter changes

3Shape

If removable support structure is used during additive manufacturing, then manufacturing complexity increases, but achievable swirl angles are improved

Engineering Contradiction:

Improveswirl angleVSAvoidsupport structure requirements

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

The patent applies the self-service principle by designing the ceiling surface to be self-supported during additive manufacturing through its vaulted geometry. The curved surface maintains sufficient structural rigidity to support itself without requiring removable support structures, thereby achieving high swirl angles while avoiding the complexity and post-processing requirements associated with support material removal

Inventive Principle:

Principle #25Self-service

Data Source

PatentEP4212781B1Fluid distributor passages for a fuel injector of a gas turbine and method of manufacturing

Publication Date: 2025.10.29 COLLINS ENGINE NOZZLES INC

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AI summary

A fluid distributor passage (112) produced by a process of additively manufacturing a floor (123), ceiling (125), and opposed sidewalls (122,124)of the fluid distributor passage using a build direction, wherein at least one of the floor and/or the ceiling define a swirl angle greater than 60 degrees relative to the build direction, wherein the swirl angle is 90 degrees relative to the swirl axis (A).