Abstract:
A fuel injector for a gas turbine engine of an aircraft, and more particularly a novel and unique heatshield structure for a fuel nozzle wherein a labyrinth seal is uniquely provided in the nozzle to isolate a portion of an insulating gap from an interface whereat fuel may enter the insulating gap, and the insulating gap is provided with a positive purge flow for forcing vapors out of the insulating gap.

Description:
RELATED CASE 
       [0001]    This application claims the benefit of the filing date of U.S. Provisional Application No. 60/912,458 filed Apr. 18, 2007, which is hereby incorporated herein by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates generally to injectors and nozzles for high temperature applications, and more particularly to fuel injectors and nozzles for gas turbine engines of aircraft. 
       BACKGROUND 
       [0003]    Fuel injectors for gas turbine engines on an aircraft direct fuel from a manifold to a combustion chamber of a combustor. The fuel injector typically has an inlet fitting connected to the manifold for receiving the fuel, a fuel nozzle located within the combustor for spraying fuel into the combustion chamber, and a housing stem extending between and fluidly interconnecting the inlet fitting and the fuel nozzle. The housing stem typically has a mounting flange for attachment to the casing of the combustor. 
         [0004]    Fuel injectors are usually heat-shielded because of a high operating temperatures arising from high temperature gas turbine compressor discharge air flowing around the housing stem and nozzle. The heat shielding prevents the fuel passing through the injector from breaking down into its constituent components (i.e., “coking”), which may occur when the wetted wall temperatures of a fuel passage exceed 400° F. The coke in the fuel passages of the fuel injector can build up to restrict fuel flow to the nozzle. 
         [0005]    Heretofore, injector nozzles have included annular stagnant air or insulating gaps as insulation between external walls, such as those in thermal contact with high temperature ambient conditions, and internal walls in thermal contact with the fuel. In order to accommodate differential expansion of the internal and external walls while minimizing thermally induced stresses, the walls heretofore have been anchored at one end and free at the other end for relative movement. If the downstream tip ends of the walls are the ends left free for relative movement, even a close fitting sliding interface between the downstream tip ends can allow fuel to pass into the air gap formed between the walls. This can result in carbon being formed in the air gap, which carbon is not as good an insulator as air. In addition, the carbon may build up to a point where it blocks venting of the air gap to the air gap in the stem, which can lead to an accumulation of fuel in the air gap. This can lead to diminished nozzle service life. 
       SUMMARY OF THE INVENTION 
       [0006]    The present invention provides, inter alia, a novel and unique fuel injector for a gas turbine engine of an aircraft, and more particularly a novel and unique heatshield structure for a fuel nozzle. In accordance with the invention, a labyrinth seal is uniquely provided in the nozzle to isolate a portion of an insulating gap from an interface whereat fuel may enter the insulating gap. Additionally, the insulating gap is provided with a positive purge flow for forcing vapors out of the insulating gap. Although the invention is particularly applicable to fuel injectors and nozzles for gas turbine engines, principles of the invention also are more generally applicable to other applications, particularly high temperature applications where insulating gaps are provided in the nozzle and into which an ambient fluid may enter through an interface between relatively moving parts of the nozzle. 
         [0007]    As is preferred, the labyrinth seal is formed by labyrinth grooves in an unrestrained tip region of the nozzle to trap fuel (or other vapors depending on the application) as they enter and prevent fuel from moving further upstream into the insulating gap. In combination with the grooves, venting is added upstream to set up a favorable pressure differential to purge any fuel emanating from the grooves out of the fuel nozzle. 
         [0008]    The shape, number and/or location of the grooves can vary. The venting for purging can also vary according to shape, number and location for favorable pressure drop, depending on the application. 
         [0009]    Accordingly, a nozzle comprises an inlet at an upstream end of the nozzle, a discharge outlet at a downstream end of the nozzle, and a fluid delivery passage extending between the inlet and the discharge outlet. An internal annular wall bounds one side of the fluid delivery passage along a length thereof, whereby such wall is in heat transfer relation with fluid passing through the fluid delivery passage. An external annular wall is interposed between the internal annular wall and ambient conditions surrounding the nozzle, and the external and internal walls have downstream tip ends that are relatively longitudinally movable at an interface, as may arise from relative thermal growth during use of the nozzle under high temperature conditions. Additionally, an internal insulating gap is interposed between the internal and external walls to insulate the internal wall from ambient temperature conditions external to the nozzle. One of the internal and external walls has formed therein, proximate the downstream tip ends thereof, at least one labyrinth groove opening toward the other one of the internal and external walls for capturing ambient fluid that may enter into the insulating gap through the interface. 
         [0010]    As is preferred, the nozzle further comprises at least one vent opening communicating with the insulating gap at an upstream end of the nozzle for providing a purge flow from the vent opening toward the interface. The vent opening may fluidly connect to a central through duct that extends axially through the nozzle and which is surrounded by the internal wall. 
         [0011]    The nozzle may be further characterized by one or more of the following features: 
         [0012]    a. the fluid delivery passage may include at least one vane configured to impart swirling to the fluid flowing to the discharge outlet; 
         [0013]    b. the insulating gap may surround the internal wall and the external wall may surround the insulating gap; 
         [0014]    c. the internal wall may surround the insulating gap, and the insulating gap may surround a central duct extending axially through the nozzle; 
         [0015]    d. the central duct may include swirl vanes for imparting a rotary motion to an ambient fluid flowing through the central duct; 
         [0016]    e. the insulating gap may contain air, another gas or an insulating material, or may be evacuated; and/or 
         [0017]    f. the insulating gap may extend substantially the entire length of the fluid delivery passage. 
         [0018]    According to another aspect of the invention, a fuel injector for a gas turbine engine comprises a nozzle as above described for spraying fuel into a combustion chamber, and a housing stem for supporting the nozzle in the combustion chamber. The housing stem includes an internal fuel conduit for supplying fuel to the fluid inlet of the nozzle. 
         [0019]    The fuel injector may be further characterized by one or more of the following features: 
         [0020]    a. the housing stem may include an external wall surrounding the fuel conduit, and an insulating gap between the external wall and fuel conduit, which insulating gap may be in fluid communication with the insulating gap of the nozzle; 
         [0021]    b. the insulating gap may contain air, another gas or an insulating material, or may be evacuated; 
         [0022]    c. the housing stem may extend from a fuel line fitting to the nozzle for connecting the nozzle to the fitting; 
         [0023]    d. the housing stem and nozzle may be rigidly and fixedly connected together as a single component that can be inserted into and located within an opening in a combustor casing; and/or 
         [0024]    e. the housing stem may include a flange extending outwardly away from the stem, the flange having an attachment device to allow the stem to be attached to the gas turbine engine. 
         [0025]    According to a further aspect of the invention, a fuel injector for a gas turbine engine comprises a housing stem and a nozzle, the nozzle including an internal wall in heat transfer relation with fuel flowing through the nozzle, and an external wall in heat transfer relation with ambient air. The internal and external walls have downstream tip ends that are relatively moveable at an interface due to relative thermal growth during operation of the engine. An internal insulating gap is disposed between the internal and external walls to provide a heat shield for the internal wall, and one of the internal and external walls has formed therein, proximate the downstream tip ends thereof, at least one labyrinth groove opening toward the other one of the internal and external walls for capturing ambient fluid that may enter into the insulating gap through the interface. 
         [0026]    According to still another aspect of the invention, a fuel injector for a gas turbine engine comprises a fitting having a first fuel passage for receiving fuel; a nozzle having a second fuel passage for dispensing fuel; a housing stem extending between and interconnecting said fitting and said nozzle for i) supporting said fuel nozzle, and ii) directing fuel flow from said fitting to said nozzle, said housing stem having an internal bore defined by internal walls extending longitudinally through the stem; and a fuel conduit disposed in the bore in said housing stem and closely surrounded by the internal walls of said housing stem. The fluid conduit has a first connection with the fitting and a second connection with the nozzle to fluidly interconnect the fuel passage in said fitting with the fuel passage in said nozzle, the internal bore in the housing stem is fluidly closed at the first connection to prevent fuel flowing around the fuel conduit in the bore, and the fuel conduit is spaced apart from the internal walls of the housing stem such that an air gap surrounds the fuel conduit along substantially the entire length of the fuel conduit between the fuel conduit and the housing stem. A vent passage internal of the nozzle has a first, upstream end fluidly connected to the air gap, and a second end at a downstream end of the nozzle. The vent passage is formed by co-axial cylindrical vent conduits, with one residing within the other and a labyrinth groove structure defined between the vent conduits forming at least a portion of the vent passage. A vent hole into the vent passage is provided for creating a pressure differential between the upstream end of the vent passage and the downstream end of the vent passage. 
         [0027]    Other features and advantages of the present invention will become further apparent upon reviewing the following detailed description and attached drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0028]    In the annexed drawings: 
           [0029]      FIG. 1  is a partial cross-sectional view of a portion of a gas turbine engine illustrating a fuel injector constructed in accordance with the present invention; 
           [0030]      FIG. 2  is a fragmentary cross-sectional view of a portion of the injector nozzle, showing one configuration of a labyrinth seal and purge venting; 
           [0031]      FIG. 3  is a fragmentary cross-sectional view similar to  FIG. 2 , but showing another configuration; 
           [0032]      FIG. 4  is a fragmentary cross-sectional view similar to  FIG. 2 , but showing another configuration; 
           [0033]      FIG. 5  is a fragmentary cross-sectional view similar to  FIG. 2 , but showing another configuration; 
           [0034]      FIG. 6  is a fragmentary cross-sectional view similar to  FIG. 2 , but showing another configuration; 
           [0035]      FIG. 7  is a fragmentary cross-sectional view similar to  FIG. 2 , but showing another configuration; 
           [0036]      FIG. 8  is a fragmentary perspective view showing an exemplary arrangement of labyrinth grooves and threads provided on a fuel swirler; and 
           [0037]      FIG. 9  is a fragmentary perspective view showing another exemplary arrangement of labyrinth grooves and threads on a nozzle housing. 
       
    
    
     DETAILED DESCRIPTION 
       [0038]    As above indicated, the principles of the present invention have particular application to fuel injectors and nozzles for gas turbine engines and thus will be described below chiefly in this context. It will of course be appreciated, and also understood, that the principles of the invention may be useful in other applications including, in particular, other fuel nozzle applications and more generally applications where a fluid is injected by a nozzle especially under high temperature conditions. In addition, an air blast type nozzle/injector is illustrated in the drawings, but the principles of the invention may be applied to other types of nozzles and injectors, such as pressure atomizer, multiple fuel circuit nozzles with one or more inlets or fuel conduits, etc. Such other nozzles/injectors may or may not have the illustrated central duct. 
         [0039]    Referring now in detail to the drawings and initially to  FIG. 1 , a gas turbine engine for an aircraft is illustrated generally at  10 . The gas turbine engine  10  includes an outer casing  12  extending forwardly of an air diffuser  14 . The casing and diffuser enclose a combustor, indicated generally at  20 , for containment of burning fuel. The combustor  20  includes a liner  22  and a combustor dome, indicated generally at  24 . An igniter, indicated generally at  25 , is mounted to the casing  12  and extends inwardly into the combustor for igniting fuel. The above components can be conventional in the art and their manufacture and fabrication are well known. 
         [0040]    A fuel injector, indicated generally at  30 , is received within an aperture  32  formed in the engine casing  12  and extends inwardly through an aperture  34  in the combustor liner  22 . The fuel injector  30  includes a fitting  36  external of the engine casing for receiving fuel, as by connection to a fuel manifold or line; a fuel nozzle, indicated generally at  40 , disposed within the combustor for dispensing fuel; and a housing stem  42  interconnecting and structurally supporting the nozzle  40  with respect to fitting  36 . The fuel injector is suitably secured to the engine casing, as by means of an annular flange  41  that may be formed in one piece with the housing stem  42  proximate the fitting  36 . The flange extends radially outward from the housing stem and includes appropriate means, such as apertures, to allow the flange to be easily and securely connected to, and disconnected from, the casing of the engine using, as by bolts or rivets. 
         [0041]    As best seen in  FIG. 2  when viewed in conjunction with  FIG. 1 , the housing stem  42  includes a central, longitudinally-extending bore  52  extending the length of the housing stem. A fuel conduit  58  extends through the bore and fluidly interconnects fitting  36  and nozzle  40 . The fuel conduit  58  has an internal passage  62  for the passage of fuel. The fuel conduit  58  is surrounded by the bore  52  of the housing stem, and an annular insulating gap  63  is provided between the external surface of the fuel conduit  58  and the walls of the bore  52 . The insulating gap  63  provides thermal protection for the fuel in the fuel conduit. The housing stem  42  has a thickness sufficient to support nozzle  40  in the combustor when the injector is mounted to the engine, and is formed of material appropriate for the particular application. 
         [0042]    The housing stem  42  may be formed integrally with fuel nozzle  40 , and preferably in one piece with at least a portion of the nozzle. The lower end of the housing stem includes an annular outer shroud  94  circumscribing the longitudinal axis “A” of the nozzle  40 . The outer shroud  94  is connected at its downstream end to an annular outer air swirler  96 , such as by welding at  98 . The outer air swirler  96  includes an annular wall  97  forming a continuation of the shroud  94  and from which swirler vanes  99  may project radially outwardly to an annular shroud  100 . The shroud  100  is tapered inwardly at its downstream end  101  to direct air in a swirling manner toward the central axis “A” at the discharge end  102  of the nozzle. 
         [0043]    A second outer air swirler (not shown) may also be provided, in surrounding relation to the air swirler  96 . The second air swirler may also include radially-outward projecting swirler vanes and an annular shroud. The outermost shroud may have a geometry at its downstream end that also directs air in a swirling manner toward the central axis “A” at the discharge end of the nozzle. 
         [0044]    The annular wall  97  surrounds a downstream wall  104  of the shroud  100  that forms a continuation of an annular prefilmer  110  that is attached as by brazing to the upstream end of the prefilmer wall  104 . The annular prefilmer  110  and prefilmer wall  104  surround a fuel swirler  111 , and together the prefilmer, prefilmer wall and fuel swirler form internal walls of the nozzle that define therebetween a fuel passage  112 , to direct fuel through the nozzle. The fuel swirler may be provided with vanes  118  that direct the fuel in a swirling manner as it flows past the vanes. The prefilmer  110  may have a fuel inlet opening  113  at its upstream end, that receives the downstream end of fuel conduit  58 . The fuel conduit  58  may be fluidly sealed and rigidly and permanently attached within the opening in an appropriate manner, such as by welding or brazing. The prefilmer wall  104  may be tapered inwardly at its downstream end  114  to direct fuel in a swirling manner toward the central axis “A” at the discharge end  102  of the nozzle. An air swirler  120  with radially-extending swirler blades  122  may also be provided in an air passage (duct)  117  bounded by the radially inner surface of an inner annular heat shield  126  that is disposed radially inwardly of the fuel swirler as seen in  FIG. 2 . The air swirler  120  directs air in a swirling manner along the central axis “A” of the nozzle to the discharge end  102  of the nozzle. 
         [0045]    The inner heat shield  126  extends centrally within the nozzle. The inner heat shield and fuel swirler respectively form external and internal walls of the nozzle that have an insulating gap  128  therebetween that functions to protect the fuel from the elevated temperatures. The insulating gap  128  may be connected by a suitable passage in the nozzle to the insulating gap  63  of the housing stem for venting, if desired. 
         [0046]    In use, the inner heat shield  126  will be in thermal contact with ambient conditions external to the nozzle, such being for instance a high temperature gas, in particular high temperature gas turbine compressor discharge air that passes through duct  117  in the nozzle. Consequently, the inner heat shield will usually expand longitudinally (along the axis A) more than the fuel swirler  111  that is in thermal contact with the fuel and thus cooled by the fuel. To avoid high stresses from being induced in the nozzle, the inner heat shield and fuel swirler may have the upstream ends thereof anchored, i.e. fixed, with respect to one another, while the downstream tip ends thereof may be free to move relative to one another in the longitudinal direction, i.e. along the axis A of the nozzle. 
         [0047]    To minimize the passage of fuel into the insulating gaps, the tip ends of the tip ends of the fuel swirler  111  and inner heat shield  126  may be provided with a close fitting sliding interface indicated at  134 . Notwithstanding the close fit, fuel may still pass into the insulating gap  128  formed between the walls  111  and  126 . This can result in carbon being formed in the insulating gap, which carbon is not as good an insulator as air. In addition, the carbon may build up to a point where it blocks venting of the insulation gap  126 , and this can lead to an accumulation of fuel in the insulation gap. This may possibly lead to diminished nozzle service life. 
         [0048]    In accordance with the present invention, the fuel swirler  111  has formed is its radially inner wall surface facing the heat shield  126  proximate the downstream tip end thereof (i.e. at the interface  134 ), at least one and preferably a plurality (four shown) of labyrinth grooves  140  that open toward the heat shield for capturing ambient fluid that may enter into the insulating gap  128  through the interface  134 . The labyrinth grooves are axially spaced apart by annular threads  142  that engage the interior wall surface of the heat shield with a slip fit. Further details of the labyrinth grooves and threads are shown in  FIG. 8 , where only the fuel swirler is shown. 
         [0049]    The labyrinth grooves  140  and threads  142  in effect form a labyrinth seal that performs a sealing action by controlling the passage of fluid through a plurality of chambers formed by the grooves. Fluid can become entrapped in the labyrinth chambers, where it may be forced into a vortex-like motion that acts to prevent its escape and also repel additional fluid from entering. 
         [0050]    Additionally (or alternatively), the insulating gap  128  is provided with a positive purge flow for forcing vapors out of the insulating gap. To this end, at least one vent opening  144  is provided in the heat shield  126  at the upstream end thereof to communicate the upstream end of insulating gap with the central duct. This will set up a pressure drop between the vent opening and the downstream end of the interface  134  for producing a purge flow that forces vapors out of the insulating gap. Although only one vent opening is shown, a plurality of annularly spaced apart vent openings may be provided in the heat shield. 
         [0051]    If desired, the labyrinth grooves  140  and threads  142  additionally or alternatively may be provided on the radially outer surface of the inner heat shield  126  as illustrated  FIG. 3 , wherein the same reference numerals are used to denote like components. In this version of the nozzle, the balance of the structure is otherwise identical to the nozzle shown in  FIG. 2 . 
         [0052]    Turning now to  FIG. 4 , another nozzle construction according to the invention is shown at  160 . In the nozzle  160 , an annular insulating gap  162  is provided between an internal prefilmer  164  and a wall  166  formed as part of the shroud  168 . The prefilmer  164  forms with a fuel swirler  170  an annular fuel passage  172  that directs fuel through the nozzle. The fuel swirler may be provided with vanes  174  that direct the fuel in a swirling manner as it flows past the vanes. The prefilmer  164  may have a fuel inlet opening at its upstream end, that receives the downstream end of a fuel conduit  180 . The fuel conduit  180  and related structure may be as above described in respect of  FIGS. 1 and 2 . 
         [0053]    The prefilmer  164  may be tapered inwardly at its downstream end to direct fuel in a swirling manner toward the central axis “A” at the discharge end of the nozzle. An air swirler  184  may be provided in the central air passage  186  bounded by the radially inner surface of an inner annular heat shield  188  that is disposed radially inwardly of the fuel swirler. In addition, an outer air swirler  190  includes an annular wall  192  that forms a continuation of the shroud and from which swirler vanes  194  may project radially outwardly to an annular shroud  196 . 
         [0054]    The insulating gap  162  may be in fluid communication with the insulating gap  200  in housing stem  202 . The insulating gap  162  provides thermal protection for internal components in thermal contact with the fuel flowing through the nozzle. As seen in  FIG. 4 , a second insulating gap  204  may be provided radially outwardly of the downstream end of the insulating gap  162  between the shroud wall  166  and the annular wall  192 . 
         [0055]    In use, the shroud  168  and wall  166  will be in thermal contact with ambient conditions external to the nozzle, such being high temperature gas turbine compressor discharge air that passes around the nozzle. Consequently, the shroud walls will usually expand longitudinally (along the axis A) more than the prefilmer  164  that is in thermal contact with the fuel. To avoid high stresses from being induced in the nozzle, the shroud wall  166  and prefilmer  164  have the upstream ends thereof anchored, i.e. fixed, with respect to one another, while the downstream tip ends thereof may be free to move relative to one another at a close-fitting sliding interface  208  in the longitudinal direction, i.e. along the axis A of the nozzle. In addition, the tip end of the wall  192  may be free to move relative to the tip end of the prefilmer at a close-fitting sliding interface  210 . The interface  208  closes the downstream end of the insulating gap  162  while the interface  210  closes the downstream end of the insulating gap  204 . 
         [0056]    Notwithstanding the close fit at the interface  208 , fuel may still pass into the insulating gap formed between the walls. This can result in carbon being formed in the insulating gap, which carbon is not as good an insulator as air. In addition, the carbon may build up to a point where it blocks venting of the insulation gap, which can lead to an accumulation of fuel in the insulation gap. This may possibly lead to diminished nozzle service life. 
         [0057]    Here, the shroud wall  166  has formed is its radially inner wall surface facing the prefilmer proximate the downstream tip end thereof (i.e. at the interface  208 ), at least one and preferably a plurality (four shown) of labyrinth grooves  216  that open toward the heat shield for capturing ambient fluid that may enter into the insulating gap  162  through the interface  208 . The labyrinth grooves are axially spaced apart by annular threads  218  that engage the radially outer wall surface of the prefilmer with a slip fit. Further details of the labyrinth grooves and threads are shown in  FIG. 9 , where only the outer shroud is shown. 
         [0058]    As before, the labyrinth grooves  216  and threads  218  in effect form a labyrinth seal that performs a sealing action by controlling the passage of fluid through a plurality of chambers formed by the grooves. Fluid can become entrapped in the labyrinth chambers, where it may be forced into a vortex-like motion that acts to prevent its escape and also repel additional fluid from entering. 
         [0059]    Additionally (or alternatively), the insulating gap  162  is provided with a positive purge flow for forcing vapors out of the insulating gap. This may be effected by one or more vent openings  222  in the same manner described above in connection with  FIG. 2 . 
         [0060]    If desired, the labyrinth grooves  140  and threads  142  additionally or alternatively may be provided on the radially outer surface of the prefilmer  164  as illustrated  FIG. 5 , wherein the same reference numerals are used to denote like components. In this version of the nozzle, the balance of the structure is otherwise identical to the nozzle shown in  FIG. 4 . 
         [0061]      FIG. 6  shows a further modification where the labyrinth grooves and threads are formed in the radially inner surface of the shroud extension wall  230 , whereas  FIG. 7  shows the same configuration as  FIG. 6 , except the labyrinth grooves and threads are formed on the radially outer surface of the prefilmer for interaction with the radially inner surface of the shroud wall. In both instances, purge venting can be provided as above described. 
         [0062]    The nozzle described above may be formed from an appropriate heat-resistant and corrosion resistant material, such as those known to those skilled in the art. The nozzle may be formed and assembled using conventional manufacturing techniques. 
         [0063]    The skilled person will also appreciate that a nozzle may be provided with one or more of the herein describe insulating gaps and associated labyrinth seals. 
         [0064]    Regarding the labyrinth grooves, the same have been described as axially spaced apart, annular grooves. The grooves, however, may be otherwise configured and otherwise shaped. For instance, they may be interconnected, and/or they may be formed by one or more helical grooves as well. 
         [0065]    Likewise, other types of venting configurations may be employed. The vent need not be limited to one or more holes as above described, nor necessarily be located at an upstream position. Other configurations can provide for a pressure in the gap higher than the pressure in the labyrinth groove(s). By way of further example, the vent could be provided additionally or alternatively by a slip fit between the upstream end of the inner heat shield  126  and the inner diameter of the shroud  94 . 
         [0066]    While several embodiments of a nozzle have been described above, it should be apparent to those skilled in the art that other nozzle (and stem) designs can be configured in accordance with the present invention. The invention is not limited to any particular nozzle design, but rather is appropriate for a wide variety of commercially-available nozzles, including nozzles for other applications where the nozzle is subjected to ambient high temperature conditions. 
         [0067]    The principles, preferred embodiments and modes of operation of the present invention have been described in the foregoing specification. The invention which is intended to be protected herein should not, however, be construed as limited to the particular form described as it is to be regarded as illustrative rather than restrictive. Variations and changes may be made by those skilled in the art without departing from the scope and spirit of the invention.