Metal Matrix Flexible Seal Assembly for Torsion and Wear
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Solution Overview
Problem
Existing flexible seal assemblies in industrial applications like gas turbines and aerospace turbines face issues with leakage, durability, temperature resistance, and wear due to high torsional rigidity and limited longitudinal flexure, leading to inefficiencies and operational challenges.
Innovation Solution
A flexible seal assembly comprising multiple layers of metal matrix sheet material made from randomly arranged thin wire segments, sintered together to form a semi-rigid sheet, encapsulated within a metal casing that provides low torsional rigidity and high longitudinal flexure, allowing the seal to maintain effectiveness even with component movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid seal assemblies are used to maintain seal integrity, then sealing effectiveness is improved, but wear on adjacent components increases due to high torsional rigidity
Solution Approach 1:
The patent changes the mechanical parameters of the seal assembly by using a metal matrix composite material with specific properties: low torsional rigidity (to reduce wear on adjacent components) and high longitudinal flexure (to maintain seal integrity during movement). This parameter optimization resolves the contradiction between sealing effectiveness and component wear.
Solution Approach 2:
The patent employs a composite metal matrix material formed by sintering randomly arranged wire segments, creating a material with anisotropic mechanical properties. The composite structure provides low torsional rigidity while maintaining high longitudinal flexure and wear resistance, simultaneously addressing both sealing effectiveness and component protection.
2Adaptability or versatility
If flexible materials are used to accommodate movement, then longitudinal flexure is improved, but temperature resistance and durability deteriorate
Solution Approach 1:
The metal matrix composite material combines the flexibility needed for longitudinal movement with the thermal and mechanical durability required for high-temperature turbine environments. The sintered wire structure provides both flexure and temperature resistance, resolving the contradiction between adaptability and reliability.
Solution Approach 2:
The patent optimizes the material parameters to achieve high longitudinal flexure while maintaining temperature resistance through the metal matrix composition and sintering process, allowing the seal to withstand both movement and high-temperature conditions.
3Ease of manufacture
If traditional cloth or laminate seals are used to fill gaps, then ease of installation is improved, but sealing performance and durability deteriorate due to leakage and brittleness
Solution Approach 1:
The patent replaces traditional cloth or laminate seals with a metal matrix composite material that forms a unified, durable sealing structure. The composite material eliminates the brittleness and leakage issues of traditional seals while maintaining ease of installation as a single-component assembly.
Solution Approach 2:
The metal matrix is formed from segmented wire pieces that are sintered together, creating a structure that combines the simplicity of modular assembly with the durability of a unified metal seal, improving both ease of manufacture and sealing performance.
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 reduces wear on components, enhances operational lifetime, and maintains a seal during movement, improving operational efficiency by accommodating flexure while protecting the metal matrix material.
Implementation Method 1
The metal matrix sheet material can be made from a plurality of segments of thin wire arranged in a random fashion to create a sheet structure, and which are then sintered together to form a semi-rigid sheet
Data Source
AI summary
Flexible seal assemblies having a relatively low torsional rigidity and high longitudinal flexure to thereby allow the flexible seal assembly to flex between adjacent components and maintain a seal, even when movement between adjacent components occurs, is described. In some embodiments, the flexible seal assembly includes one or more layers of metal matrix material, the metal matrix material being comprised of a plurality of short segments of thin wire arranged randomly and sintered together to form a semi-rigid sheet. The one or more layers of metal matrix material can be sandwiched between an upper casing and a lower casing of a metal alloy casing. In various embodiments, additional features are provided for helping to make sure the seal assembly stays together, such as spot welds formed through the seal assembly, an S-shaped casing, and a recess/protrusion feature provided on adjacent layers of metal matrix material.