Hollow-wall heat shield for fuel injector component

Patent metadata

Field	Value
Publication number	US-2016003156-A1
Application number	US-201414769386-A
Country	US
Kind code	A1
Filing date	Mar 13, 2014
Priority date	Mar 14, 2013
Publication date	Jan 7, 2016
Grant date	—

Abstract

A fuel injector component ( 94 ) comprises a body ( 100 ), an elongate void ( 124 ) and a plurality of bores ( 129 ). The body ( 100 ) has a first surface ( 125 ) and a second surface ( 130, 132 ). The elongate void ( 124 ) is enclosed by the body ( 100 ) and is integrally formed between portions of the body ( 100 ) defining the first surface ( 125 ) and the second surface ( 130, 132 ). The plurality of bores ( 129 ) extends into the second surface 130 to intersect the elongate void ( 124 ). A process for making a fuel injector component ( 94 ) comprises building an injector component body ( 100 ) having a void ( 124 ) and a plurality of ports ( 129 ) connected to the void ( 124 ) using an additive manufacturing process that utilizes a powdered building material, and removing residual powdered building material from void through the plurality of ports ( 129 ).

First claim

1 . A fuel injector component comprising:
a body having:
a first surface; and
a second surface;
an elongate void enclosed by the body, the void being integrally formed between portions of the body defining the first surface and the second surface; and a bore extending into the second surface to intersect the elongate void.

2 . The fuel injector component of claim 1 wherein the body includes a plurality of bores extending into the second surface to intersect the elongate void.

3 . The fuel injector component of claim 2 wherein:
the elongate void includes first and second distal ends; and
the plurality of bores are spaced from the first and second distal ends.

4 . The fuel injector component of claim 3 wherein each of the plurality of bores extends transverse to the elongate void.

5 . The fuel injector component of claim 3 wherein:
the first surface is configured to engage a fuel flow;
the second surface is configured to engage an air flow; and
the elongate void extends from the first distal end to the second distal end in a direction in which the air flow is configured to flow.

6 . The fuel injector component of claim 2 wherein the elongate void produces dead-air space in the body that spaces portions of the first surface from portions of the second surface.

7 . The fuel injector component of claim 2 wherein the body is a monolithic structure.

8 . The fuel injector component of claim 7 wherein the body is fabricated using a rapid manufacturing process.

9 . The fuel injector component of claim 2 wherein the body comprises an annular structure including:
an outer-facing surface comprising the first surface; and
an inner-facing surface comprising the second surface.

10 . The fuel injector component of claim 9 wherein the plurality of bores are arranged in a circumferential array about the outer facing surface.

11 . The fuel injector component of claim 10 and further comprising:
a circumferential indentation in the outer facing surface adjacent the elongate void;
multiple pedestals extending from the circumferential indentation within the elongate void to connect to a portion of the body forming the inner facing surface; and
a plurality of fuel passages extending through the multiple pedestals, respectively, to connect the outer facing surface to the inner facing surface.

12 . The fuel injector component of claim 11 and further comprising a cover coupled to the body adjacent the outer facing surface to form a manifold within the circumferential indentation and to seal the circumferential array of bores.

13 . The fuel injector component of claim 2 and further comprising a plurality of swirl vanes extending from the first or second surface.

14 . A process for making a fuel injector component for use in a gas turbine engine, the process comprising:
building an injector component body using an additive manufacturing process that utilizes a powdered building material, the injector component body comprising:
a first surface configured to be in thermal communication with a fuel flow;
a second surface configured to be in thermal communication with an air flow;
a void substantially enclosed by the body, the void being formed by portions of the body defining the first surface and the second surface; and
a plurality of ports extending into the second surface to intersect the void; and
removing residual powdered building material from the void through the plurality of ports.

15 . The process for making a fuel injector component of claim 14 and further comprising:
vibrating the injector component body to facilitate removal of the residual powdered building material within the void.

16 . The process for making a fuel injector component of claim 14 and further comprising:
directing a flow of compressed air into the void to facilitate removal of the residual powdered building material.

17 . The process for making a fuel injector component of claim 14 and further comprising:
machining the injector component body to remove material.

18 . The process for making a fuel injector component of claim 17 wherein machining the injector component body further comprises:
smoothing a surface of the body.

19 . The process for making a fuel injector component of claim 17 wherein machining the injector component body further comprises:
shaping a plurality of swirl vanes in a surface of the body.

20 . The process for making a fuel injector component of claim 14 wherein building the injector component body further comprises:
forming a trench in the first surface to form a fuel manifold;
forming pedestals extending from the trench within the void to connect to a portion of the injector component body forming the second surface; and
forming passages in the pedestals to link the first surface with the second surface.

21 . The process for making a fuel injector component of claim 20 and further comprising:
joining a cover to the injector component body to close-off the plurality of ports.

22 . The process for making a fuel injector component of claim 20 and further comprising:
joining a cover to the injector component body to seal the fuel manifold.

23 . The process for making a fuel injector component of claim 14 wherein:
the void is elongate and comprises first and second distal ends;
the plurality of ports are spaced from the first and second distal ends; and
each of the plurality of ports extends transverse to the elongate void.

24 . A fuel injector made the process of claim 14 .

Assignees

• United Technologies Corp

Inventors

• Hanson Russell B

Classifications

• F23R3/286

  having fuel-air premixing devices (F23R3/30 takes precedence) · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• F02C7/222 Primary

  Fuel flow conduits, e.g. manifolds · CPC title

• F23R2900/00018

  Manufacturing combustion chamber liners or subparts · CPC title

• F23R3/50

  Combustion chambers comprising an annular flame tube within an annular casing (toroidal combustion chambers F23R3/52) · CPC title