Monolithic Diffuser and Deswirl Structure for Gas Turbine
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Solution Overview
Problem
Existing gas turbine engine diffuser and deswirl fluid flow structures are bulky, heavy, and costly to manufacture, with inefficient aerodynamic performance due to leakage between parts.
Innovation Solution
A monolithic, unitary diffuser and deswirl flow structure composed of hollow, elongate tube structures arranged annularly, with a self-supporting outer wall defining flow passages that include diffuser and deswirl portions, manufactured using additive manufacturing techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional multi-part diffuser and deswirl structures are used, then structural strength and robustness are maintained, but weight increases and manufacturing complexity increases
Solution Approach 1:
The patent combines multiple separate components (diffuser structure, deswirl structure, and support structures) into a single monolithic flow structure. This integration eliminates the need for multiple discrete parts while maintaining all necessary functions, thereby reducing weight and simplifying manufacturing processes.
Solution Approach 2:
The monolithic flow structure performs multiple functions simultaneously: it acts as a diffuser to reduce fluid velocity, a deswirl mechanism to remove rotational motion from the fluid, and a structural support element. This multi-functionality consolidates what would traditionally require separate components into one unified structure.
2Ease of manufacture
If traditional multi-part structures are used, then aerodynamic sealing can be achieved, but manufacturing time and assembly complexity increase
Solution Approach 1:
By integrating the diffuser, deswirl, and support structures into a single monolithic component, the patent eliminates assembly operations and associated sealing requirements. The seamless construction removes potential leak paths that would exist at joints between separate parts, thereby maintaining aerodynamic sealing while dramatically reducing manufacturing time.
Solution Approach 2:
While the overall structure is monolithic, the flow passages within it are segmented into distinct functional regions (diffuser portion, deswirl portion, straight portion) that are formed as integral parts of the single structure. This allows complex internal flow paths to be created without requiring external assembly.
3Ease of operation
If traditional assembled structures are used, then structural support is provided, but assembly difficulty and time increase
Solution Approach 1:
The patent integrates support structures directly into the monolithic flow structure, eliminating the need for separate assembly operations. The support features are formed as integral parts of the single component during manufacturing, thereby simplifying installation while maintaining structural integrity.
4Productivity
If multiple separate components are used, then manufacturing flexibility is maintained, but manufacturing costs increase
Solution Approach 1:
By consolidating multiple functions into a single monolithic structure, the patent reduces the total number of parts that need to be manufactured, stored, and managed. This integration streamlines the supply chain and manufacturing processes, thereby reducing overall manufacturing costs despite the complexity of the internal flow paths.
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 provides improved aerodynamic performance, reduced weight and manufacturing costs, and simplified assembly, while maintaining structural strength and robustness.
Implementation Method 1
The plurality of flow passages respectfully include a diffuser portion, which is proximate the first portion and configured to diffuse a fluid flow from a compressor wheel
Implementation Method 2
The plurality of flow passages respectfully include a deswirl portion, which is proximate the second portion and configured to deswirl the fluid flow from the diffuser portion
Data Source
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AI summary
A diffuser and deswirl flow structure includes a plurality of tube structures with an outer wall that is hollow and elongate and that extends between a first portion and a second portion. The plurality of tube structures is disposed in an annular arrangement about the longitudinal axis. The flow structure also includes a plurality of flow passages extending through the tube structures. The plurality of flow passages extend from the first portion to the second portion, respectively. The plurality of flow passages respectfully include a diffuser portion, which is proximate the first portion and configured to diffuse a fluid flow from a compressor wheel. The plurality of flow passages respectfully include a deswirl portion, which is proximate the second portion and configured to deswirl the fluid flow from the diffuser portion. The outer wall defines the diffuser portion and the deswirl portion. The outer wall is self-supporting.