Monolithic Fuel Nozzle Assembly for Lower Manufacturing Complexity

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Solution Overview

Problem

Conventional manufacturing methods for fuel injector components in turbomachinery involve complex multi-step processes using weld and braze joints, leading to increased manufacturing time and cost.

Innovation Solution

A monolithic body for a fuel injector is manufactured using additive manufacturing, integrating a mount, stem, and heat shield portions, allowing for reduced complexity and cost through a single unitary design that can accommodate various nozzle and manifold configurations, with interfaces for easy assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional machining methods (casting, milling, drilling, electro-discharge machining) are used to manufacture fuel injector components, then satisfactory manufacturing quality is achieved, but manufacturing complexity, time, and cost increase due to multi-step processes and weld/braze joints

Engineering Contradiction:

Improvemanufacturing qualityVSAvoidmanufacturing complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent merges multiple separate fuel injector components (mount portion, stem portion, heat shield portion) into a single monolithic body manufactured through additive manufacturing. This integration eliminates the need for multiple machining steps, weld joints, and braze joints, directly reducing manufacturing complexity while maintaining precision through the additive process's inherent control over geometry and material deposition.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent replaces conventional mechanical machining processes (milling, drilling, electro-discharge machining) and joining processes (welding, brazing) with additive manufacturing technology. This substitution eliminates the multi-step mechanical manufacturing sequence, reducing both complexity and manufacturing time while achieving the required manufacturing precision through digital model control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If conventional machining methods are used to manufacture fuel injector components, then satisfactory manufacturing quality is achieved, but manufacturing time and cost increase

Engineering Contradiction:

Improvemanufacturing qualityVSAvoidmanufacturing time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

By combining multiple components into a single monolithic structure, the patent reduces the total number of manufacturing operations required. The additive manufacturing process can produce the entire assembly in one continuous build operation, eliminating sequential machining steps and joining operations, thereby significantly reducing manufacturing time while maintaining quality.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The additive manufacturing process replaces time-consuming conventional machining and joining operations with a more efficient digital fabrication process. The monolithic design allows for direct production of the final assembly geometry, eliminating intermediate steps and reducing overall manufacturing cycle time while preserving manufacturing precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If multiple separate components are assembled using weld and braze joints, then functional requirements are met, but assembly complexity and manufacturing cost increase

Engineering Contradiction:

Improvefunctional performanceVSAvoidmanufacturing ease

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent integrates multiple functional components into a single monolithic body, eliminating the need for weld and braze joints. This integration maintains all necessary functional connections and interfaces while removing the complexity of joining processes, making manufacturing easier and more cost-effective while preserving reliability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The additive manufacturing process replaces mechanical joining methods (welding, brazing) with a direct fabrication process. The monolithic structure is built as a single unit with all functional features integrated, eliminating the need for joining operations and associated complexities while maintaining the functional performance required for reliable operation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS20260063297A1Monolithic fuel nozzle assembly manufactured using additive manufacturing

Publication Date: 2026.03.05 PRATT & WHITNEY CANADA CORP

AI summary

A monolithic body and fuel injector with the monolithic body include a mount portion, a stem portion, and a heat shield portion. The stem portion and the heat shield portion extend from the first surface of the mount portion. The heat shield portion circumscribes at least a portion of the stem portion. The second surface of the mount portion defines a first interface, and a distal end of the stem portion defines a second interface for joining the monolithic body with components of the fuel injector.