Composite Thrust Chamber Cooling Passages With Curved Turnarounds

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Solution Overview

Problem

Conventional thrust chamber assemblies experience thermally induced stress and pressure loss due to abrupt cooling fluid turn-arounds, which affect the overall propulsive efficiency.

Innovation Solution

A ceramic composite tubular structure with additively manufactured cooling passages having turn-around angles less than 180°, formed by a monolithic ceramic preform with integrated CMC face sheets, evenly distributing cooling fluid and reducing thermal stresses.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If abrupt turn-arounds or corners are used in cooling fluid passages, then the device complexity is reduced, but thermally induced stress increases and cooling fluid temperature increases

Engineering Contradiction:

Improvepassage geometry complexityVSAvoidthermally induced stress

Core Design Contradiction:

Device complexityVSStress or pressure

Solution Approach 1:

The patent applies curvature by replacing abrupt corners with curved transitions in the cooling fluid passages. The curved geometry allows smooth flow direction changes, reducing flow separation and thermal stress concentration while maintaining relatively simple passage routing.

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Device complexity

If large turning corners are used in cooling fluid passages, then the device complexity is reduced, but pressure loss increases

Engineering Contradiction:

Improvepassage geometry complexityVSAvoidpressure loss

Core Design Contradiction:

Device complexityVSLoss of energy

Solution Approach 1:

The curved transition geometry minimizes flow separation and turbulence in the turn-around sections, reducing pressure loss compared to sharp corners while avoiding the complexity of optimized aerodynamic contours.

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Stress or pressure

If curved pathway portions with angles less than 180 degrees are used, then thermally induced stress is reduced, but the manufacturing precision requirements increase

Engineering Contradiction:

Improvethermally induced stressVSAvoidcurved passage geometry precision

Core Design Contradiction:

Stress or pressureVSManufacturing precision

Solution Approach 1:

The patent optimizes the curvature radius and transition angle parameters of the cooled passage to achieve smooth flow direction changes. By carefully selecting these geometric parameters, the design reduces thermal stress while maintaining manufacturability through conventional fabrication tolerances.

Inventive Principle:

Principle #35Parameter changes

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 effectively reduces thermal stresses and pressure loss, enhancing the propulsive efficiency of the thrust chamber assembly by evenly distributing cooling fluid and improving thermal management.

Implementation Method 1

a first pathway portion (305) adjacent the outer surface (205), and a second pathway portion (315) adjacent the inner surface (200)

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Data Source

PatentUS20250361844A1Composite tubular structure

Publication Date: 2025.11.27 GENERAL ELECTRIC CO

AI summary

A thrust chamber assembly includes a monolithic preform defining a combustion chamber and a nozzle. The monolithic preform has a tubular shape and includes a first end, a second end opposite the first end, an inner surface, and an outer surface. The monolithic preform defines a plurality of fluid inlets disposed at the first end, a plurality of fluid outlets disposed at the first end, and a plurality of fluid passages between the inner surface and the outer surface. The plurality of fluid passages are in fluid communication with the plurality of fluid inlets and the plurality of fluid outlets. The plurality of fluid passages comprise a first pathway portion, a second pathway portion, and a curved portion between the first pathway portion and the second pathway portion.