Integral Turbine Casing Manifold for Thermal Control

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Solution Overview

Problem

Existing gas turbine engine casings face challenges with excessive deformation, thermal expansion, and weight addition due to separable flanges and assemblies, which affect engine performance and thermal control.

Innovation Solution

The development of an integral, unitary turbine casing and manifold structure using additive manufacturing, which eliminates flanges and sub-assemblies, allowing for improved thermal control, reduced weight, and enhanced engine efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If separable flanges and assemblies are used in turbine casings, then assembly and disassembly is easier, but weight increases and thermal control effectiveness decreases

Engineering Contradiction:

Improveassembly and disassemblyVSAvoidcasing weight

Core Design Contradiction:

Ease of operationVSWeight of moving object

Solution Approach 1:

The patent merges the turbine casing and manifold into a single integral, unitary structure formed by additive manufacturing. This eliminates the need for separate flanges and assemblies, directly resolving the contradiction by removing the weight penalty associated with multiple components while maintaining ease of operation through the manufacturing process itself.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent changes the manufacturing parameter from traditional subtractive or assembly-based methods to additive manufacturing. This parameter change enables the creation of an integral structure that would be impossible or impractical to produce through conventional means, simultaneously achieving weight reduction and improved thermal control.

Inventive Principle:

Principle #35Parameter changes

2Ease of operation

If separable flanges and assemblies are used in turbine casings, then assembly and disassembly is easier, but thermal control effectiveness decreases

Engineering Contradiction:

Improveassembly and disassemblyVSAvoidthermal control effectiveness

Core Design Contradiction:

Ease of operationVSTemperature

Solution Approach 1:

The integration of the manifold into the casing creates continuous thermal control pathways that are interrupted by flanges in conventional designs. This merging eliminates thermal breaks and improves the effectiveness of thermal control structures while maintaining operational ease through additive manufacturing.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integral structure allows for optimized local thermal control features to be positioned precisely where needed without being constrained by flange locations. Thermal control rings and fluid conduits can be strategically placed to maximize thermal management effectiveness at critical locations.

Inventive Principle:

Principle #3Local quality

3Weight of moving object

If integral unitary structure is used, then weight is reduced and thermal control is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvecasing weightVSAvoidmanufacturing process

Core Design Contradiction:

Weight of moving objectVSEase of manufacture

Solution Approach 1:

The patent changes the manufacturing parameter from traditional methods to additive manufacturing, which is specifically capable of producing integral unitary structures with complex internal geometries. This parameter change resolves the contradiction by making the complex structure manufacturable through an advanced process that handles complexity inherently.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

Additive manufacturing introduces a new dimension of manufacturing capability by building structures layer-by-layer in three dimensions, rather than assembling pre-fabricated components. This dimensional approach to manufacturing enables the creation of complex integral structures that would be impossible to produce through conventional assembly methods.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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

This solution achieves improved thermal control, reduced weight, and enhanced engine efficiency by allowing for better positioning of thermal control rings and more efficient heat transfer fluid distribution within the gas turbine engine.

Implementation Method 1

manifold extended in fluid communication to a turbine section of the gas turbine engine... improved thermal control... more efficient heat transfer fluid distribution

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentUS12305516B2Gas turbine engine with a fluid conduit system and a method of operating the same

Publication Date: 2025.05.20 GENERAL ELECTRIC DEUT HLDG GMBH

AI summary

A method of operating a gas turbine engine comprising: extracting a flow of air from a compressor section of the gas turbine engine into a first conduit; flowing the extracted flow of air through the first conduit to a first location at a turbine section of the turbine section, wherein a second conduit is in fluid communication with the turbine section at a second location; flowing a heat transfer fluid to a first heat exchanger positioned in thermal communication with the flow of air through the first conduit, the heat transfer fluid in thermal communication with the extracted flow of air through the first conduit via the first heat exchanger; and modulating, via a flow control device, a portion of the flow of air extracted from the first conduit to the second conduit downstream of the first heat exchanger.