Tesla-Type Turbo-Engine Disc Stack Design
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Solution Overview
Problem
Tesla-type turbo-machines face inefficiencies due to high losses at the compressor inlet and turbine outlet, as well as compressor inlet nozzles, which have not been adequately addressed by previous designs, including those by McLean and Hicks, and result in structural integrity issues at high rotational speeds.
Innovation Solution
A turbo-engine with an extremely thin composite rotor disc featuring uninterrupted tangentially wound fibers, preferably carbon fibers, and a stack of discs separated by spacers to maintain geometry and structural integrity, along with a reverse fluid flow direction in the turbine to reduce losses, and a single disc stack combining compressor, combustion chamber, and turbine functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If Tesla-type bladeless turbine is used, then device complexity is reduced, but efficiency deteriorates due to high losses at inlet and outlet
Solution Approach 1:
The turbine is segmented into multiple disc stacks arranged in series, with each disc having progressively smaller diameter from inlet to outlet. This segmentation allows the turbine to process fluid in stages, reducing the velocity and energy loss at each interface between discs, thereby maintaining simplicity while improving efficiency.
2Power
If high rotational speed is achieved, then power output is improved, but structural integrity deteriorates due to centrifugal forces
Solution Approach 1:
The rotor discs are constructed from composite materials that provide high strength-to-weight ratio, enabling the discs to withstand the high centrifugal forces generated at rotational speeds necessary for optimal Tesla-type turbine performance without compromising structural integrity.
3Loss of energy
If disc thickness is reduced, then inlet losses are reduced, but structural strength deteriorates
Solution Approach 1:
Composite materials enable the discs to be made extremely thin to minimize inlet losses while maintaining sufficient structural strength through the superior strength-to-weight ratio of composite construction.
Solution Approach 2:
The turbine is divided into multiple thin disc stacks rather than using a single thick disc, allowing each individual disc to be thin enough to reduce inlet losses while the stacked configuration maintains overall structural integrity.
4Loss of energy
If conventional turbine design is used, then efficiency is improved, but device complexity and mass increase
Solution Approach 1:
The turbine merges the functions of multiple turbine stages into a single integrated disc stack configuration, achieving the efficiency of multi-stage turbines while maintaining the simplicity and low mass characteristic of bladeless Tesla-type designs.
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
This configuration significantly reduces inlet and outlet losses, enhances structural integrity, and achieves higher efficiency and lower mass and cost compared to conventional engines, allowing operation at high temperatures and rotational speeds.
Implementation Method 1
The working fluid interaction with the rotor is through viscosity of the fluid and its adhesion to the discs.
Implementation Method 2
The working fluid interaction with the rotor is through viscosity of the fluid and its adhesion to the discs.
Implementation Method 3
The disc attains stiffness and maintains precise geometry under hoop stress generated by high rotational speed.
Implementation Method 4
The thickness of these end plates increases with radius in the axial direction, away from the disc stack, resulting in the bending moments generated by the centrifugal force
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention is directed to a turbo-engine, particularly internal combustion engine, comprising a housing and therein a bladeless turbine section (30; 42; 67) of the stacked disc- or Tesla-type construction, wherein the turbine section (30; 42; 67) has a plurality of closely spaced discs (32; 49; 61 ) arranged for common rotation about a rotation axis in the housing, said turbine section (30; 42; 67) is adapted for passing with tangential flow components a working fluid stream from a radially inner region to a radially outer region of said turbine section (30; 42; 67) while adopting energy from said working fluid stream for rotating the discs (30; 49; 61). Preferably, the turbo-engine further comprises a compressor section (40; 66) of the stacked disc- or Tesla-type construction having a plurality of closely spaced discs (45; 61 ) arranged for common rotation about said rotation axis and a combustion zone (41; 64), wherein said compressor section (40; 66) being arranged coaxially with- and radially inwardly of the turbine section (30; 42; 67) with the combustion zone (41; 64) provided radially between the compressor section and the turbine section.