Integral Boss Structure for Fire-Safe Gas Turbine Seal Mounting

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Solution Overview

Problem

Gas turbine engines face challenges in meeting stringent fire testing requirements without adding significant weight or cost, particularly for non-metallic seals that are susceptible to fire damage, leading to potential fuel or oil leaks and fire hazards.

Innovation Solution

An additively manufactured boss with a heat shield and radial/tangential ribs provides thermal isolation and fire protection for non-metallic seals, incorporating a thin metal shield element and fireproof material in a cavity, enhancing fire resistance without substantial weight or cost increases.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional fire protection methods are used for non-metallic seals, then fire resistance is improved, but weight and cost increase significantly

Engineering Contradiction:

Improvefire resistanceVSAvoidweight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The heat shield is nested within the existing boss structure, with the shield forming an inner cavity that contains the non-metallic seal. This nested configuration provides fire protection while utilizing the existing boss geometry, avoiding additional external components that would increase weight.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The heat shield is implemented as a thin-walled metallic structure that forms a protective cavity around the seal. This thin-film approach provides thermal isolation and fire resistance without requiring thick protective layers, thereby minimizing weight increase.

Inventive Principle:

Principle #30Flexible shells and thin films

2Reliability

If traditional fire protection methods are used for non-metallic seals, then fire resistance is improved, but cost increases significantly

Engineering Contradiction:

Improvefire resistanceVSAvoidcost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The heat shield is integrated directly into the boss structure as a single monolithic component. This merging of the shield with the existing boss eliminates the need for separate protective components and complex assembly processes, thereby reducing manufacturing cost.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention utilizes additive manufacturing technology to produce the boss with integrated heat shield. This manufacturing parameter change enables complex geometries to be produced cost-effectively without requiring multiple machining operations or assembled parts, reducing overall manufacturing cost.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If a heat shield with distal edge portion is used, then fire protection is improved, but device complexity increases

Engineering Contradiction:

Improvefire protectionVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The boss structure serves multiple functions: it provides mechanical support for the seal, contains the cooling air passage, and incorporates the heat shield for fire protection. This multi-functionality reduces the need for additional separate components, thereby managing complexity while improving fire protection.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The heat shield is nested within the boss structure with its distal edge portion extending toward the seal. This nested configuration provides fire protection while utilizing the existing boss geometry, avoiding additional external components that would increase complexity.

Inventive Principle:

Principle #7Nested doll (Nesting)

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 solution significantly increases fire resistance for gas turbine engine seals while maintaining lightweight and cost-effective design, with radial and tangential ribs providing structural integrity and improved airflow.

Implementation Method 1

a heat shield. The heat shield is integrally extendible from the outboard base portion and along the component to surround the inner wall at a distance to define a cavity with the inner wall

Methodology Applied

Scientific EffectThermal isolation: Thermal Insulation

Implementation Method 2

an inner wall extendible from the inboard base portion and along the component to surround a non-metallic seal of the component and having an interior diameter configured to compress the non-metallic seal radially inwardly

Methodology Applied

Scientific EffectRadial compression: Compression

Data Source

PatentEP4703564A1Boss with integral fire protection

Publication Date: 2026.03.04 PRATT & WHITNEY CANADA CORP

Figure 1
Figure 2A~2B
Figure 3~4

AI summary

A boss (130) with which a component (110) of a gas turbine engine (20) is attachable is provided. The boss (130) includes a base (140) comprising inboard and outboard base portions (141, 142), an inner wall (150) extendible from the inboard base portion (141) and along the component (110) to surround a seal (120) of the component (110) and having an interior diameter (ID1) configured to compress the seal (120) radially inwardly and a heat shield (160). The heat shield (160) is integrally extendible from the outboard base portion (142) and along the component (110) to surround the inner wall (150) at a distance (D) to define a cavity (170) with the inner wall (150). The heat shield (160) includes a distal edge portion (175) having a terminal diameter (TD) less than a diameter (D2) of the outboard base portion (142).