Unitary Additive Thrust Bearing with Integrated Cooling Channels
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Solution Overview
Problem
Conventional thrust bearing assemblies are complex and costly to manufacture, with limited cooling capabilities, leading to increased operating temperatures and risk of fracture under high loads, and are composed of multiple pieces that are prone to axial load stress and wear.
Innovation Solution
The thrust bearing assembly is designed as a unitary, additively manufactured component with integrated cooling channels within the body and pads, allowing for dynamic movement of pads relative to the body and independent of each other, and featuring varying cooling channel shapes and sizes to enhance fluid flow turbulence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional thrust bearings are formed of multiple pieces joined together, then the bearing can be manufactured using traditional casting and machining processes, but the joints between components are subject to axial loads and increased risk of fracture
Solution Approach 1:
The patent combines multiple separate components (ring carrier, socket joint, and pad) into a single monolithic structure formed by additive manufacturing. This eliminates the joints between components that were previously subject to axial loads and fracture risk, while maintaining all necessary functional features through integrated design.
2Ease of manufacture
If traditional machining processes are used to form cooling passages in thrust bearings, then the manufacturing process is well-established, but the cooling passages are limited by machining capabilities and cannot achieve complex geometries
Solution Approach 1:
The patent replaces traditional mechanical machining processes with additive manufacturing technology. This substitution enables the creation of complex, three-dimensional cooling passage geometries within the monolithic bearing structure that cannot be achieved through conventional machining methods, while still using established metal powder bed fusion technology.
3Power
If the design of turbines is improved to operate at higher loads, then power generation efficiency increases, but the operating temperature of turbine assemblies increases
Solution Approach 1:
The patent introduces cooling fluid as an intermediary substance that absorbs and removes heat from the bearing structure. The integrated cooling passages allow cooling fluid to flow through the monolithic bearing, providing thermal management that enables the turbine to operate at higher loads and temperatures without compromising bearing reliability.
4Adaptability or versatility
If multiple components are used in thrust bearing assembly, then the bearing can be assembled from separate functional elements, but the assembly complexity and cost increase with manufacturing complexity
Solution Approach 1:
The patent merges multiple functional components into a single monolithic structure that integrates the ring carrier, socket joint, and pad features. This consolidation eliminates assembly complexity while maintaining all necessary functional characteristics through the additive manufacturing process, which can create complex internal geometries and features within the single printed structure.
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 design enables efficient cooling and reduced risk of fracture, allowing the turbine to operate at higher loads while maintaining temperature control, thus improving the reliability and efficiency of thrust bearing assemblies.
Implementation Method 1
The cooling channel directs cooling fluid to one or more positions within the body and one or more positions within the pad
Data Source
AI summary
A thrust bearing assembly includes a body comprising a first outer surface and a second outer surface, and a pocket extending between an open end at the first outer surface and a closed end disposed within the body between the first outer surface and the second outer surface. The assembly includes a pad comprising a base end and a free end. The base end is coupled to the closed end of the pocket and the free end is disposed proximate the first outer surface of the body. The body and the pad are configured to be formed as a unitary component. The assembly also includes a cooling channel extending within the body and the pad. The cooling channel is configured to fluidly couple the body with the pad. The cooling channel directs cooling fluid to one or more positions within the body and one or more positions within the pad.