Monolithic Multi-Lumen Spray Bars With Fewer Fuel Manifold Joints
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Solution Overview
Problem
Traditional manufacturing methods for fuel manifolds in gas turbine engines require numerous individual components, leading to complex, expensive, and impractical assemblies with many joints, which are not optimized for fuel flow and are difficult to service.
Innovation Solution
The development of seamless, unitary, multi-lumen fuel distribution components formed through additive manufacturing, creating a single-piece structure with complex internal geometries that reduce the number of joints and enhance structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional manufacturing methods are used to assemble fuel manifolds from numerous individual components, then the assembly can be permanently bonded together through welding or brazing, but the device complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent merges dozens of individual machined components into a single monolithic fuel manifold structure. This consolidation eliminates the need for welding or brazing multiple components together, thereby reducing assembly complexity while maintaining structural integrity through the unified monolithic design.
Solution Approach 2:
The monolithic fuel manifold is designed with integrated internal flow passages that segment the fuel distribution into multiple lumens within the single structure. This allows the manifold to function as multiple components would traditionally, but without the complexity of assembling those separate components.
2Reliability
If numerous individual components are assembled to create fuel manifolds, then the components can be permanently bonded together, but the number of joints increases leading to higher manufacturing cost
Solution Approach 1:
By combining all fuel manifold components into a single monolithic structure, the patent eliminates the need for welding or brazing operations entirely. This removes the associated manufacturing costs of joining operations while ensuring uniform material properties throughout the structure without joint weaknesses.
3Strength
If traditional assembled fuel manifolds are used, then the components can be bonded together, but the assembly requires extensive external bracing for support and strengthening
Solution Approach 1:
The monolithic design integrates all structural support elements within the single fuel manifold structure. The unified construction provides inherent structural strength and rigidity without requiring additional external bracing, as the entire assembly acts as a single structurally sound unit.
4Reliability
If assembled fuel manifolds are used with multiple joints, then the components can be permanently bonded together, but the final assembly becomes impractical to service
Solution Approach 1:
The monolithic fuel manifold design eliminates all joints and connections that would require disassembly for servicing. The single integrated structure allows for easier maintenance and repair operations, as there are no welded or brazed joints to compromise integrity during servicing, and the entire unit can be inspected and maintained as one component.
Data Source
AI summary
The subject matter of this specification can be embodied in, among other things, a fuel delivery component, a substantially rigid, unitary structure formed as a single piece of material, and at least a first seamless lumen defined by the unitary structure as a first loop.