Integrally Formed Gas Turbine Stator Splitter

Solution Overview

Problem

Current stator configurations in gas turbine engines require complex assemblies with multiple components to split airflow into multiple paths, leading to increased expense, assembly complexity, and weight.

Innovation Solution

A stator configuration featuring a single, integrally formed splitter segment with radially extending stators that split airflow into outer and inner streams, including a sacrificial rub layer to prevent damage from rotor contact, and a flange for coupling to stationary structures, reducing component count and facilitating assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple separate components are used to split airflow, then flow manipulation capability is improved, but device complexity and assembly complexity increase

Engineering Contradiction:

Improveflow manipulation capabilityVSAvoidassembly complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines multiple separate stator components into a single integrally formed stator structure. The stator includes a splitter segment and multiple stator vanes that are formed as one piece, eliminating the need for separate components and complex assembly procedures while maintaining the capability to split and manipulate airflow into multiple paths.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrally formed stator structure performs multiple functions simultaneously: it splits airflow into radially outer and inner streams, guides flow along different paths, and provides structural support. The single structure incorporates both the splitter segment and stator vanes, making it a multi-functional component that replaces several separate parts.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If multiple separate components are used to split airflow, then flow manipulation capability is improved, but weight increases

Engineering Contradiction:

Improveflow manipulation capabilityVSAvoidstator weight

Core Design Contradiction:

Adaptability or versatilityVSWeight of stationary object

Solution Approach 1:

The patent combines multiple separate stator components into a single integrally formed stator structure. The stator includes a splitter segment and multiple stator vanes that are formed as one piece, eliminating the need for separate components and complex assembly procedures while maintaining the capability to split and manipulate airflow into multiple paths.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If multiple separate components are used to split airflow, then flow manipulation capability is improved, but manufacturing cost increases

Engineering Contradiction:

Improveflow manipulation capabilityVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent combines multiple separate stator components into a single integrally formed stator structure. The stator includes a splitter segment and multiple stator vanes that are formed as one piece, eliminating the need for separate components and complex assembly procedures while maintaining the capability to split and manipulate airflow into multiple paths.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The stator is designed with a segmented structure consisting of a splitter segment and stator vanes that are integrally formed. This segmentation allows for optimized manufacturing processes such as single-step casting or additive manufacturing, reducing production complexity and cost compared to assembling multiple separate precision components.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS12044167B2Stator configuration for gas turbine engine

Publication Date: 2024.07.23 RTX CORP

AI summary

A stator configuration for a gas turbine engine including: a splitter segment, the splitter segment extending from a forward end to a rearward end, the splitter segment being configured to split an incoming fluid flow into a first, radially outer stream and a second, radially inner stream; a forward most first stator extending radially outwardly from the splitter segment, the forward most first stator being completely located downstream from the forward end of the splitter segment; a forward most second stator extending radially inwardly from the splitter segment, the splitter segment, the forward most first stator and the forward most second stator being formed as a single, integrally formed structure, the forward most first stator positioned closer to the forward end relative to a distance between the forward most second stator and the forward end and the forward most second stator positioned closer to the rearward end relative to a distance between the forward most first stator and the rearward end, wherein the splitter segment defines a radially outward boundary of the second, radially inner stream such that an outer tip of a rotor passes in close proximity to the splitter segment at the radially outward boundary of the second, radially inner stream defined by the splitter segment; and a sacrificial rub layer located within a pocket formed in a radially inner surface of the splitter segment that faces the outer tip of the rotor at the radially outward boundary of the second, radially inner stream defined by the splitter segment.