Combustion chamber wall and a method of manufacturing a combustion chamber wall
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
F23R-003/00
B22F-003/105
B22F-005/00
B22F-005/10
C21B-009/04
출원번호
US-0608943
(2015-01-29)
등록번호
US-10260749
(2019-04-16)
우선권정보
GB-1403404.5 (2014-02-27)
발명자
/ 주소
Harding, Stephen Charles
출원인 / 주소
ROLLS-ROYCE plc
대리인 / 주소
Oliff PLC
인용정보
피인용 횟수 :
0인용 특허 :
4
초록▼
A combustion chamber wall is hollow, has a first surface and a second surface and includes a plurality of polyhedron shaped chambers defined by a matrix of integral interconnected walls. The walls of the chambers in a first layer define the first surface of the combustion chamber wall and the walls
A combustion chamber wall is hollow, has a first surface and a second surface and includes a plurality of polyhedron shaped chambers defined by a matrix of integral interconnected walls. The walls of the chambers in a first layer define the first surface of the combustion chamber wall and the walls of the chambers in a third layer define the second surface of the combustion chamber wall. The chambers are fluidly interconnected by apertures extending through the integral interconnected walls of the chambers for the flow of coolant there-between. The walls of the chambers in the first layer have apertures extending there-through to supply coolant into the first layer and the walls of the chambers in the third layer have apertures extending there-through to supply coolant from the third layer into the combustion chamber. The combustion chamber wall is manufactured by additive layer manufacture.
대표청구항▼
1. An annular combustion chamber wall, which is hollow, the annular combustion chamber wall comprising: a first surface located on an outer side of the annular combustion chamber wall;a second surface located on an inner side of the annular combustion chamber wall forming an inner side of a combusti
1. An annular combustion chamber wall, which is hollow, the annular combustion chamber wall comprising: a first surface located on an outer side of the annular combustion chamber wall;a second surface located on an inner side of the annular combustion chamber wall forming an inner side of a combustion chamber;a plurality of polyhedron shaped chambers defined by a matrix of integral interconnected walls, the plurality of polyhedron shaped chambers being arranged in at least two layers between the first surface and the second surface including: a first layer formed by the integral interconnected walls of the polyhedron shaped chambers and defining the first surface of the annular combustion chamber wall; anda second layer formed by the integral interconnected walls of the polyhedron shaped chambers and defining the second surface of the annular combustion chamber wall;a plurality of apertures extending through the integral interconnected walls of the polyhedron shaped chambers for the flow of coolant there-between, the apertures fluidly interconnecting the polyhedron shaped chambers in each layer to the polyhedron shaped chambers in each adjacent layer, adjacent polyhedron shaped chambers share a common wall, a first plurality of apertures of the plurality of apertures extending through the integral interconnected walls of the polyhedron shaped chambers in the first layer from the first surface to supply coolant into the first layer, and a second plurality of apertures of the plurality of apertures extending through the integral interconnected walls of the polyhedron shaped chambers in the second layer to the second surface to supply coolant from the second layer into the combustion chamber;at least one rib formed on an interior surface of at least one of the interconnected walls within at least one of the plurality of polyhedron shaped chambers, the at least one rib projecting from the interior surface towards another one of the interconnected walls that is on an opposite side of the polyhedron shaped chamber from the interior surface and into the at least one polyhedron shaped chamber, the at least one rib extending along a length of the annular combustion chamber wall; anda plurality of circumferential segments joined together to form the annular combustion chamber wall, each having a circumferential ends, the circumferential ends of each of the plurality of circumferential segments including a tongue or a groove configured to be inserted into a groove or to receive a tongue of an adjacent circumferential segment of the plurality of circumferential segments, the circumferential ends of each of the plurality of circumferential segments being formed of solid metal or a plurality of layers of polyhedron shaped chambers. 2. The annular combustion chamber wall as claimed in claim 1, wherein all the polyhedron shaped chambers have a same shape. 3. The annular combustion chamber wall as claimed in claim 1, wherein the polyhedron shaped chambers are selected from the group consisting of: parallelogram sided cuboid shaped chambers, square based pyramid shaped chambers, rhombic dodecahedron shaped chambers, elongated dodecahedron shaped chambers, truncated dodecahedron shaped chambers, spherical shaped chambers, spheroid shaped chambers and two types of polyhedron shaped chambers. 4. The annular combustion chamber wall as claimed in claim 3, wherein: the polyhedron shaped chambers are elongated dodecahedron shaped chambers, the elongated dodecahedron shaped chambers being elongated in a longitudinal direction of the annular combustion chamber,the annular combustion chamber wall includes three layers of the elongated dodecahedron shaped chambers, andthe elongated dodecahedron shaped chambers in the first layer are adjacent to the elongated dodecahedron shaped chambers in the second layer, and the elongated dodecahedron shaped chambers in a third layer are longitudinally located between two rows of the elongated dodecahedron shaped chambers in the first layer and two rows of the elongated dodecahedron shaped chambers in the second layer. 5. The annular combustion chamber wall as claimed in claim 3, wherein the polyhedron shaped chambers are rhombic dodecahedron shaped chambers. 6. The annular combustion chamber wall as claimed in claim 1, wherein a thickness of a wall of each polyhedron shaped chamber is in a range of 0.2 to 2 mm. 7. The annular combustion chamber wall as claimed in claim 1, wherein a distance between walls of the polyhedron shaped chambers is 1 to 4 mm. 8. The annular combustion chamber wall as claimed in claim 1, wherein one or two layers of polyhedron shaped chambers are provided between the first layer and the second layer. 9. The annular combustion chamber wall as claimed in claim 1, wherein the first surface of the annular combustion chamber wall is multi-faceted and the facets are defined by walls of the polyhedron shaped chambers in the first layer. 10. The annular combustion chamber wall as claimed in claim 9, wherein a portion of the facets defined by the walls of the polyhedron shaped chambers in the first layer face in an upstream direction, the portion of the facets facing in the upstream direction include apertures extending there-through to supply coolant into the first layer. 11. The annular combustion chamber wall as claimed in claim 10, wherein the portion of the facets facing in the upstream direction have a same cross-sectional area as the portion of the facets facing in a downstream direction, such that the portion of the facets facing in the downstream direction form scoops to supply coolant through the apertures in the portion of the facets facing in the upstream direction into the first layer. 12. The annular combustion chamber wall as claimed in claim 1, wherein the first surface has at least one rib extending from the first surface in a direction away from the second surface. 13. The annular combustion chamber wall as claimed in claim 1, wherein the first surface is corrugated. 14. The annular combustion chamber wall as claimed in claim 1, wherein: the second surface is cylindrical, anddownstream walls of the polyhedron shaped chambers defining the second surface include apertures extending through the downstream walls to supply coolant from the second layer in a downstream direction into the annular combustion chamber. 15. The annular combustion chamber wall as claimed in claim 14, wherein the apertures in the downstream walls of the polyhedron shaped chambers defining the second surface have a same cross-sectional area as the downstream walls of the polyhedron shaped chambers. 16. The annular combustion chamber wall as claimed in claim 14, wherein the apertures extending through the downstream walls are fan shaped and the fan shape diverges in a direction perpendicular to the downstream direction. 17. The annular combustion chamber wall as claimed in claim 1, wherein a plurality of the polyhedron shaped chambers have at least one rib extending from at least one of the walls of the polyhedron shaped chambers into respective polyhedron shaped chambers. 18. The annular combustion chamber wall as claimed in claim 1, wherein the combustion chamber wall is formed from a superalloy selected from a group consisting of: a nickel base superalloy, a cobalt base superalloy and an iron base superalloy. 19. The annular combustion chamber wall as claimed in claim 1, wherein a thermal barrier coating is provided on the second surface of the annular combustion chamber wall. 20. A method of manufacturing an annular combustion chamber wall, which is hollow, the annular combustion chamber wall including: (i) a first surface and a second surface, and (ii) a plurality of polyhedron shaped chambers defined by a matrix of integral interconnected walls, the plurality of polyhedron shaped chambers being arranged in at least two layers between the first surface and the second surface, a first layer formed by the integral interconnected walls of the polyhedron shaped chambers and defining the first surface of the annular combustion chamber wall, and a second layer formed by the integral interconnected walls of the polyhedron shaped chambers and defining the second surface of the annular combustion chamber wall, the polyhedron shaped chambers in each layer are fluidly interconnected to the polyhedron shaped chambers in each adjacent layer by apertures extending through the integral interconnected walls of the polyhedron shaped chambers for the flow of coolant there-between, adjacent polyhedron shaped chambers share a common wall, a first plurality of apertures of the plurality of apertures extending through the integral interconnected walls of the polyhedron shaped chambers in the first layer from the first surface to supply coolant into the first layer, and a second plurality of apertures of the plurality of apertures extending through the integral interconnected walls of the polyhedron shaped chambers in the second layer to the second surface to supply coolant from the second layer into the combustion chamber, the method comprising steps of: (a) depositing layers of a metal sequentially one upon the other to form layers of a spiral wall, depositing each layer of metal in a spiral pathway, and(b) joining ends of the spiral wall to form the annular combustion chamber wall, the ends of the spiral wall being at opposite ends of the spiral pathway. 21. The method as claimed in claim 20, wherein step (b) includes rolling the spiral wall into a ring before joining the ends of the spiral wall together. 22. The method as claimed in claim 20, wherein step (a) includes: (i) depositing a first layer of a metal powder onto a platform,(ii) directing a radiation beam in at least one spiral pathway onto the first layer of metal powder deposited in step (i) to melt and sinter the metal powder to form a first layer of the spiral wall,(iii) depositing a second layer of the metal powder onto the previously deposited layer of metal powder,(iv) directing the radiation beam in at least one spiral pathway onto the second layer of metal powder deposited in step (iii) to melt and sinter the metal powder to form a second layer of the spiral wall and to bond the second layer of metal powder to the previously deposited first layer of metal powder, and(v) repeating steps (iii) and (iv) a plurality of times to build up the spiral wall. 23. The method as claimed in claim 22, wherein step (ii) is selected from a group consisting of: directing a laser beam onto the first layer of metal powder, directing a microwave beam onto the first layer of metal powder, and directing an electron beam onto the first layer of metal powder. 24. The method as claimed in claim 22, wherein step (iv) is selected from a group consisting of: directing a laser beam onto the second layer of metal powder, directing a microwave beam onto the second layer of metal powder, and directing an electron beam onto the second layer of metal powder. 25. A method of manufacturing an annular combustion chamber wall, which is hollow, the annular combustion chamber wall including: (i) a first surface located on an outer side of the annular combustion chamber wall, (ii) a second surface located on an inner side of the annular combustion chamber wall forming an inner side of a combustion chamber, (iii) a plurality of polyhedron shaped chambers defined by a matrix of integral interconnected walls, the plurality of polyhedron shaped chambers being arranged in at least two layers between the first surface and the second surface including a first layer formed by the integral interconnected walls of the polyhedron shaped chambers and defining the first surface of the annular combustion chamber wall, and a second layer formed by the integral interconnected walls of the polyhedron shaped chambers and defining the second surface of the annular combustion chamber wall, (iv) a plurality of apertures extending through the integral interconnected walls of the polyhedron shaped chambers for the flow of coolant there-between, the apertures fluidly interconnecting the polyhedron shaped chambers in each layer to the polyhedron shaped chambers in each adjacent layer, adjacent polyhedron shaped chambers share a common wall, a first plurality of apertures of the plurality of apertures extending through the integral interconnected walls of the polyhedron shaped chambers in the first layer from the first surface to supply coolant into the first layer, and a second plurality of apertures of the plurality of apertures extending through the integral interconnected walls of the polyhedron shaped chambers in the second layer to the second surface to supply coolant from the second layer into the combustion chamber, (v) at least one rib formed on an interior surface of at least one of the interconnected walls within at least one of the plurality of polyhedron shaped chambers, the at least one rib projecting from the interior surface towards another one of the interconnected walls that is on an opposite side of the polyhedron shaped chamber from the interior surface and into the at least one polyhedron shaped chamber, the at least one rib extending along a length of the annular combustion chamber wall, and (vi) a plurality of circumferential segments joined together to form the annular combustion chamber wall, each having a circumferential ends, the circumferential ends of each of the plurality of circumferential segments including a tongue or a groove configured to be inserted into a groove or to receive a tongue of an adjacent circumferential segment of the plurality of circumferential segments, the circumferential ends of each of the plurality of circumferential segments being formed of solid metal or a plurality of layers of polyhedron shaped chambers, the method comprising: manufacturing the annular combustion chamber wall by additive layer manufacture;manufacturing the annular combustion chamber wall in circumferential segments by the plurality of circumferential segments joined together; andbuilding the annular combustion chamber wall by assembling each of the plurality of circumferential segments layer by layer and joining the circumferential ends of each of the plurality of circumferential segments together. 26. The method as claimed in claim 25, wherein the additive layer manufacture is selected from a group consisting of: directing a laser beam onto layers of metal powder, directing a microwave beam onto layers of metal powder, and directing an electron beam onto layers of metal powder. 27. The method as claimed in claim 25, wherein the polyhedron shaped chambers are one of rhombic dodecahedron shaped chambers and elongated dodecahedron shaped chambers, andthe method further comprising building the walls of the polyhedron shaped chambers at an angle of 45°. 28. An annular combustion chamber wall, which is hollow, the annular combustion chamber wall comprising: a first surface located on an outer side of the annular combustion chamber wall;a second surface located on an inner side of the annular combustion chamber wall forming an inner side of a combustion chamber;a plurality of polyhedron shaped chambers defined by a matrix of integral interconnected walls, the plurality of polyhedron shaped chambers being arranged in at least two layers between the first surface and the second surface including: a first layer formed by the integral interconnected walls of the polyhedron shaped chambers and defining the first surface of the annular combustion chamber wall; anda second layer formed by the integral interconnected walls of the polyhedron shaped chambers and defining the second surface of the annular combustion chamber wall;a plurality of apertures extending through the integral interconnected walls of the polyhedron shaped chambers for the flow of coolant there-between, the apertures fluidly interconnecting the polyhedron shaped chambers in each layer to the polyhedron shaped chambers in each adjacent layer, adjacent polyhedron shaped chambers share a common wall, a first plurality of apertures of the plurality of apertures extending through the integral interconnected walls of the polyhedron shaped chambers in the first layer from the first surface to supply coolant into the first layer, and a second plurality of apertures of the plurality of apertures extending through the integral interconnected walls of the polyhedron shaped chambers in the second layer to the second surface to supply coolant from the second layer into the combustion chamber; anda plurality of circumferential segments joined together to form the annular combustion chamber wall, each having a circumferential ends, the circumferential ends of each of the plurality of circumferential segments including a tongue or a groove configured to be inserted into a groove or to receive a tongue of an adjacent circumferential segment of the plurality of circumferential segments, the circumferential ends of each of the plurality of circumferential segments being formed of a plurality of layers of polyhedron shaped chambers.
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이 특허에 인용된 특허 (4)
Sterman Albert P. (Cincinnati OH) Wakeman Thomas G. (Cincinnati OH) Williams Jesse J. (Cincinnati OH), Combustion chamber construction.
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