Patent Publication Number: US-2020300389-A1

Title: Fluid couplings and methods for additive manufacturing thereof

Description:
This patent application is a divisional of U.S. patent application Ser. No. 15/825,947 filed Nov. 29, 2017, which is a divisional of U.S. patent application Ser. No. 14/707,713 filed May 8, 2015, which claims priority to U.S. Provisional Patent Application No. 61/991,163 filed May 9, 2014, the disclosures of which are hereby incorporated herein by reference in their entireties. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Technical Field 
     This disclosure relates generally to a fluid coupling and, more particularly, to connecting conduits of a fluid coupling together as well as methods for manufacturing the fluid coupling. Such a fluid coupling may be included in various industrial and consumer equipment including, but not limited to, turbine engines. 
     2. Background Information 
     A turbine engine may include a fluid circuit for delivering or circulating fluid such as fuel, lubricant and/or coolant. Such a fluid circuit may include a fluid coupling that includes a plurality of fluid conduits connected together. A typical transition between adjacent fluid conduits may be relatively abrupt due to manufacturing constraints. Such an abrupt transition may create flow disturbances and/or lead to formation of coke where, for example, the fluid flowing within the fluid conduits is jet fuel. 
     There is a need in the art for improved connections between fluid conduits as well as improved methods for forming conduits of a fluid coupling. 
     SUMMARY OF THE DISCLOSURE 
     According to an aspect of the invention, a method is provided involving an additive manufacturing system. This method includes a step of forming a first fluid conduit using the additive manufacturing system. The method also includes a step of providing a fluid coupling. The fluid coupling includes the first fluid conduit and a second fluid conduit. The first fluid conduit is connected to and fluidly coupled with the second fluid conduit. The first fluid conduit has a first configuration. The second fluid conduit has a second configuration that is different than the first configuration. 
     According to another aspect of the invention, an assembly is provided for a fluid delivery system. This assembly includes a fluid coupling, which includes a first fluid conduit, a second fluid conduit and a compliant intermediate fluid conduit. The intermediate fluid conduit connects and fluidly couples the first fluid conduit to the second fluid conduit. The intermediate fluid conduit is formed integral with the first and the second fluid conduits. 
     According to still another aspect of the invention, another assembly is provided for a fluid delivery system. This assembly includes a fluid coupling, which includes a first fluid conduit and a second fluid conduit. The first fluid conduit is connected to and fluidly coupled with the second fluid conduit at a joint. The first fluid conduit is interlocked with the second fluid conduit at the joint. 
     The method may include a step of forming the second fluid conduit using the additive manufacturing system. 
     The second fluid conduit may be formed integral with the first fluid conduit. 
     The first fluid conduit may be connected to and fluidly coupled with the second fluid conduit during the forming of the first and the second fluid conduits. 
     The method may include a step of fluidly coupling the first fluid conduit to the second fluid conduit after the forming of the first and the second fluid conduits. 
     The method may include a step of connecting and fluidly coupling the first fluid conduit to the second fluid conduit. The first fluid conduit may be formed discretely from the second fluid conduit. 
     A joint between the first fluid conduit and the second fluid conduit may have a non-rectangular configuration. 
     The first fluid conduit may interlock with the second fluid conduit. 
     The method may include a step of connecting and fluidly coupling the first fluid conduit to the second fluid conduit through a compliant intermediate fluid conduit. The intermediate fluid conduit may be formed integral with the first and the second fluid conduits. 
     The first fluid conduit may have a cross-section with a first shape. The second fluid conduit may have a cross-section with a second shape that is different than (or the same as) the first shape. In addition or alternatively, the first fluid conduit may form a first flowpath with a first cross-sectional area. The second fluid conduit may form a second flowpath with a second cross-sectional area that is different than (or the same as) the first cross-sectional area. 
     The intermediate fluid conduit may be adapted to allow movement between the first and the second fluid conduits. 
     The intermediate fluid conduit may extend along a substantially straight centerline. 
     The intermediate fluid conduit may extend along a curved and/or compound centerline. 
     The first fluid conduit may have a first configuration. The second fluid conduit may have a second configuration that is different than (or the same as) the first configuration. 
     The assembly may include a fluid source and a turbine engine component. The turbine engine component may be fluidly coupled to the fluid source through the fluid coupling. 
     The first fluid conduit may be formed integral with the second fluid conduit. 
     The foregoing features and the operation of the invention will become more apparent in light of the following description and the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a block diagram of a fluid delivery system configured to deliver fluid to a component. 
         FIG. 2  is a side sectional illustration of a portion of a turbine engine fuel injector. 
         FIG. 3  is a cross-sectional illustration of the fuel injector of  FIG. 2  at a first location. 
         FIG. 4  is a cross-sectional illustration of the fuel injector of  FIG. 2  at a second location. 
         FIGS. 5-12  are partial side illustrations of various alternative embodiments of a fluid coupling for the fuel injector of  FIG. 2 . 
         FIG. 13  is a side cutaway illustration of a geared turbine engine. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 1  is a block diagram of a fluid delivery system  20  configured to deliver fluid to a component  22 . The fluid delivery system  20  may also be configured to receive fluid from the component  22  as illustrated by the dashed line  24 ; e.g., circulate the fluid through the component  22 . 
     The component  22  may be configured as or include a heat exchanger, a bearing, a gear train, a nozzle (see  FIG. 2 ), a combustor, an augmentor or a diffuser. For ease of description, the component  22  is described below and illustrated in  FIG. 2  as nozzle (e.g., a nozzle plate) of a gas turbine engine fuel injector. The fluid delivery system  20 , however, is not limited to delivering fluid to the exemplary components described above. For example, the component  22  may be configured as any fluid receiving device or system of a turbine engine. Furthermore, the fluid delivery system  20  may also be configured to deliver the fluid to a plurality of components in serial and/or in parallel, some or all of which may have the same configuration or different configurations. 
     The fluid may be heat exchange fluid (e.g., liquid and/or gaseous coolant), and delivered to cool or heat the component  22 . The fluid may be actuator fluid (e.g., hydraulic liquid or compressed air), and delivered to actuate the component  22 . The fluid may be fuel, and delivered for distribution by or combustion within the component  22 . The fluid delivery system  20 , however, is not limited to delivering the exemplary fluids described above. 
     The fluid delivery system  20  of  FIG. 1  includes a fluid pump  26  and a fluid source  28 ; e.g., a reservoir, a tank, a sump or an inlet. The fluid delivery system  20  also includes a fluid circuit  30  that fluidly couples the components  22 ,  26  and  28  together in an open loop, or in a closed loop as shown by the dashed line  24 . 
     The fluid circuit  30  includes a plurality of fluid couplings  32 - 34 . Each of the couplings  32 - 34  includes one or more coupling devices, which form a fluid flowpath through which the fluid may be directed between respective components. Examples of a coupling device include, but are not limited to, a conduit (e.g., a pipe, hose or duct), a manifold, a splitter, a valve, a regulator, a meter and a filter. 
     The coupling  32  may extend between and fluidly couples the fluid source  28  to the fluid pump  26 . The coupling  33  may extend between and fluidly couples the fluid pump  26  to the component  22 . The coupling  34  may extend between and fluidly couples the component  22  to the fluid source  28 . 
     At least one of the couplings  32 - 34  includes a coupling assembly  36 . This coupling assembly  36  forms at least a portion of one of the couplings  32 - 34 . For ease of description, the coupling assembly  36  is described below and illustrated in  FIG. 1  as being included in and forming at least a portion of the coupling  33 . However, in other embodiments, the coupling assembly  36  may alternatively be included in and form at least a portion of one of the other couplings  32  or  34 . Furthermore, in some embodiments, the fluid circuit  30  may include a plurality of coupling assemblies, in parallel and/or in serial, that partially or completely form one or more of the couplings  32 - 34 . 
     Referring to  FIG. 2 , the coupling assembly  36  includes a plurality of fluid conduits  38  and  40 . Each of these fluid conduits  38  and  40  may be configured as a pipe, a hose, a duct or any other generally tubular object for directing fluid therethrough. 
     The first fluid conduit  38  may have a generally tubular sidewall  42  that forms a fluid flowpath  44 ; e.g., a generally cylindrical fluid flowpath. This fluid flowpath  44  extends along a centerline  46  through the first fluid conduit  38 . 
     Referring to  FIG. 3 , the sidewall  42  may have an annular circular cross-sectional geometry. The first fluid conduit  38 , however, is not limited to such a cross-sectional geometry. The sidewall  42 , for example, may alternatively have an annular elongated, rectangular and/or irregular cross-sectional geometry. Furthermore, in some embodiments, the first fluid conduit  38  may include a protrusion (or another sidewall) that provides the fluid flowpath  44  with an annular geometry as described below with reference to the second fluid conduit  40  (see  FIG. 4 ). The coupling assembly  36 , of course, is not limited to the foregoing exemplary first fluid conduit  38  configurations. 
     Referring to  FIG. 2 , the second fluid conduit  40  may have a generally tubular outer sidewall  48  and an inner protrusion  50 ; e.g., a solid cylindrical object. The sidewall  48  and protrusion  50  are configured to form a fluid flowpath  52 ; e.g., an annular fluid flowpath. This fluid flowpath  52  extends along a centerline  54  through the second fluid conduit  40  and is fluidly coupled with the fluid flowpath  44 . 
     Referring to  FIG. 4 , the sidewall  48  may have an annular circular cross-sectional geometry. The first fluid conduit  38 , however, is not limited to such a cross-sectional geometry. The sidewall  48 , for example, may alternatively have an annular elongated, rectangular and/or irregular cross-sectional geometry. Furthermore, in some embodiments, the second fluid conduit  40  may be configured without the protrusion  50 , or the protrusion  50  may be replaced with an inner sidewall. The coupling assembly  36 , of course, is not limited to the foregoing exemplary second fluid conduit  40  configurations. 
     The fluid conduits  38  and  40  are described above and illustrated in the drawings with different configurations. In particular, the first fluid conduit  38  and the second fluid conduit  40  are configured with cross-sections of different shapes. A cross-sectional area of the fluid flowpath  44  is also different (e.g., smaller) than a cross-sectional area of the fluid flowpath  52 . However, in other embodiments, the fluid conduits  38  and  40  may have substantially similar configurations. Furthermore, while the fluid conduits  38  and  40  are illustrated in the drawings with non-parallel (e.g., perpendicular or otherwise angled) centerlines  46  and  54 , in other embodiments the centerlines  46  and  54  may be parallel and even co-axial. 
     Referring to  FIG. 2 , the first fluid conduit  38  is connected to the second fluid conduit  40 . An end of the first fluid conduit  38 , for example, is connected to an end of the second fluid conduit  40 . The first fluid conduit  38  may be formed integral with the second fluid conduit  40  as illustrated in  FIG. 2 . Alternatively, referring to  FIGS. 5-7 , the first and the second fluid conduits  38  and  40  may be formed as discrete (e.g., separate) units and subsequently attached to one another via a bonded connection (and/or a mechanical connection). 
     A joint  56  between the fluid conduits  38  and  40  may various non-interlocking and interlocking configurations. Examples of a joint with a non-interlocking configuration include, but are not limited to, a beveled lap joint (see  FIG. 5 ), a modified bridle joint (see  FIG. 6 ), a butt joint and a shiplap joint. Examples of a joint with an interlocking configuration include, but are not limited to, a tabled splice joint (see  FIG. 7 ) and a dovetail joint. 
     It is worth noting, a rectangular joint  58  as illustrated in  FIG. 8  may provide a relatively abrupt transition between the fluid conduits  38  and  40 . Such an abrupt transition may cause fluid flow disturbances (e.g., turbulence) and/or lead to formation of coke where the fluid flowing within the conduits  38  and  40  is heated fuel. In contrast, the non-rectangular joint  56  embodiments of  FIGS. 5-7  are configured to provide a relatively gradual transition between the fluid conduits  38  and  40 . More particularly, fluid flowing between the fluid conduits  38  and  40  progressively interacts with different portions of the joint  56 . The gradual transition of the joint therefore may be useful in, among other things, reducing fluid flow disturbances and/or reducing formation of coke where the fluid delivery system  20  is configured for delivering fuel in a turbine engine. In addition, the joint  56  embodiments of  FIGS. 5-7  may be more durable than the joint  58  embodiment of  FIG. 8 . 
     A gap (or gaps) between the fluid conduits  38  and  40  may be filled with filler material  60 . Examples of filler material include, but are not limited to, bonding material such as braze, weld and adhesive. Another example of filler material is a seal; e.g., a metal or elastomeric seal. The filler material  60  may be operable to at least partially thermally decouple the first fluid conduit  38  from the second fluid conduit  40 . The filler material  60  may also or alternatively be operable to reduce stress at the joint  56 ,  58  where, for example, the fluid conduits  38  and  40  are subjected to opposing forces and/or moments. 
       FIG. 9  illustrates a hybrid joint  62  between the first fluid conduit  38  and the second fluid conduit  40 . In this embodiments, the first fluid conduit  38  is formed integral with the second fluid conduit  40  where a bridge  64  integrally connects the conduits  38  and  40  together. This bridge  64  may be useful when forming the first and the second fluid conduits  38  and  40  using additive manufacturing. In contrast to the embodiment of  FIG. 2 , however, gaps extend between the fluid conduits  38  and  40  that are filled with filler material  60  as described above. Thus, a seal between the fluid conduits  38  and  40  is provided by both fluid conduit  38 ,  40  material as well as the filler material  60  whereas the seal between the fluid conduits  38  and  40  of  FIG. 2  may be provided solely by the fluid conduit  38 ,  40  material. 
     The fluid conduits  38  and  40  may be substantially directly connected together as illustrated in  FIGS. 2 and 5-9 . Alternatively, referring to  FIGS. 10-12 , the fluid conduits  38  and  40  may be indirectly connected together through, for example, an intermediate fluid conduit  66 . This intermediate fluid conduit  66  may be configured as a compliant intermediate fluid conduit. The intermediate fluid conduit  66 , for example, may be configured to flex thereby allowing “towards and away” movement, “side-to-side” movement and/or “twisting” movement between the fluid conduits  38  and  40 . Thus, the intermediate fluid conduit  66  may serve to reduce the transfer of forces and/or moments between the fluid conduits  38  and  40 . 
     The intermediate fluid conduit  66  may be formed integral with the first fluid conduit  38  and/or the second fluid conduit  40 . The intermediate fluid conduit  66  may extend along a substantially straight centerline as illustrated in  FIG. 10 . Alternatively, the intermediate fluid conduit  66  may extend along a curved centerline as illustrated in  FIG. 11  and/or a compound centerline as illustrated in  FIG. 12 . The coupling assembly  36 , however, is not limited to the exemplary intermediate fluid conduit  66  configurations described above and illustrated in the drawings. 
     The coupling assembly  36  embodiments described above and illustrated in the drawings may be manufactured using various processes. One or more of the coupling assembly components  38 ,  40 ,  64  and  66  may be formed integral with one another; e.g., formed as a single unit. Alternatively or in addition, one or more of the coupling assembly components  38 ,  40 ,  64  and  66  may be formed discrete from one another; e.g., as physically separate units. These discrete components may subsequently be assembled and attached to one another; e.g., mechanically fastened and/or bonded. 
     The coupling assembly components  38 ,  40 ,  64  and  66  are described above and illustrated in the drawings as having substantially constant cross-sectional geometries. For example, the shape and the size of the first fluid conduit  38  remains substantially constant as the conduit  38  extends along its centerline  46 . Similarly, the shape and the size of the second fluid conduit  40 , the bridge  64  and the intermediate fluid conduit  66  remain substantially constant as these components  40 ,  64  and  66  extend along their centerlines. In some embodiments, however, the cross-sectional geometries (e.g., the shapes and/or the sizes) of at least a portion of one or more of the components  38 ,  40 ,  64  and  66  may change as the respective components  40 ,  64  and  66  extend along their centerlines. For example, the diameter of one or more the fluid conduits  38  and  40  may decrease or increase as they extend towards the joint  56 . The shape of one or more of the fluid conduits  38  and  40  may also or alternatively change at the joint  56  to provide a gradual transition therebetween. Of course, various other coupling assembly component configurations are also possible and are intended to be within the scope of the present disclosure. 
     The coupling assembly components  38 ,  40 ,  64  and  66  may be formed discretely and/or integral with one another using an additive manufacturing process. The term “additive manufacturing” may describe a process where an additive manufacturing system builds up a part or parts in a layer-by-layer fashion. For example, for each layer, the additive manufacturing system may spread and compact a layer of additive manufacturing material (e.g., metal powder and/or non-metal powder) and solidify one or more portions of this material layer with an energy beam; e.g., a laser beam or an electron beam. Examples of an additive manufacturing system include, but are not limited to, a laser sintering system, an electron beam system, a laser powder deposition system and an EB wire deposition system. Examples of metal(s) from which the coupling assembly  36  may be formed include, but are not limited to, nickel (Ni), titanium (Ti), steel, stainless steel, cobalt (Co), chromium (Cr), tungsten (W), molybdenum (Mo) and/or alloys including one or more of the foregoing metals such as Waspaloy, Stellite, etc. The coupling assembly components, however, are not limited to being formed using additive manufacturing or the foregoing metal materials. For example, one or more of the coupling assembly components  38 ,  40 ,  64  and  66  may also or alternatively be formed using casting, machining, milling and/or any other manufacturing process. 
     The fluid delivery system  20  of  FIG. 1  may be configured with or included in various types of apparatuses and systems. The fluid delivery system  20 , for example, may be configured in a fuel delivery system, a lubrication system and/or a cooling or heating system of a turbine engine or any other type of engine. An example of such a turbine engine  94  (e.g., a geared turbofan engine) is illustrated in  FIG. 13 . 
     The turbine engine  94  of  FIG. 13  extends along an axial centerline  96  between an upstream airflow inlet  98  and a downstream airflow exhaust  100 . The turbine engine  94  includes a fan section  102 , a compressor section  103 , a combustor section  104  and a turbine section  105 . The compressor section  103  includes a low pressure compressor (LPC) section  103 A and a high pressure compressor (HPC) section  103 B. The turbine section  105  includes a high pressure turbine (HPT) section  105 A and a low pressure turbine (LPT) section  105 B. The engine sections  102 - 105  are arranged sequentially along the centerline  96  within a housing  106 . 
     Each of the engine sections  102 - 103 B,  105 A and  105 B includes a respective rotor  108 - 112 . Each of these rotors  108 - 112  includes a plurality of rotor blades arranged circumferentially around and connected to one or more respective rotor disks. The rotor blades, for example, may be formed integral with or mechanically fastened, welded, brazed, adhered and/or otherwise attached to the respective rotor disk(s). 
     The fan rotor  108  is connected to a gear train  114 , for example, through a fan shaft  116 . The gear train  114  and the LPC rotor  109  are connected to and driven by the LPT rotor  112  through a low speed shaft  117 . The HPC rotor  110  is connected to and driven by the HPT rotor  111  through a high speed shaft  118 . The shafts  116 - 118  are rotatably supported by a plurality of bearings  120 ; e.g., rolling element and/or thrust bearings. Each of these bearings  120  is connected to the engine housing  106  by at least one stationary structure such as, for example, an annular support strut. 
     During operation, air enters the turbine engine  94  through the airflow inlet  98 , and is directed through the fan section  102  and into a core gas path  122  and a bypass gas path  124 . The air within the core gas path  122  may be referred to as “core air”. The air within the bypass gas path  124  may be referred to as “bypass air”. The core air is directed through the engine sections  103 - 105  and exits the turbine engine  94  through the airflow exhaust  100  to provide forward engine thrust. Within the combustor section  104 , fuel is injected into a combustion chamber and mixed with the core air. This fuel-core air mixture is ignited to power the turbine engine  94 . The bypass air is directed through the bypass gas path  124  and out of the turbine engine  94  through a bypass nozzle  126  to provide additional forward engine thrust. Alternatively, at least some of the bypass air may be directed out of the turbine engine  94  through a thrust reverser to provide reverse engine thrust. 
     The fluid delivery system  20  may be included in various turbine engines other than the one described above. The fluid delivery system  20 , for example, may be included in a geared turbine engine where a gear train connects one or more shafts to one or more rotors in a fan section, a compressor section and/or any other engine section. Alternatively, the fluid delivery system  20  may be included in a turbine engine configured without a gear train. The fluid delivery system  20  may be included in a geared or non-geared turbine engine configured with a single spool, with two spools (e.g., see  FIG. 13 ), or with more than two spools. The turbine engine may be configured as a turbofan engine, a turbojet engine, a propfan engine, or any other type of turbine engine. The present invention therefore is not limited to any particular turbine engine types or configurations. Furthermore, while the fluid delivery system  20  is described above as being included in a turbine engine, the system may also be configured with various non-turbine engine systems; e.g., HVAC systems, automobile systems, etc. 
     While various embodiments of the present invention have been disclosed, it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible within the scope of the invention. For example, the present invention as described herein includes several aspects and embodiments that include particular features. Although these features may be described individually, it is within the scope of the present invention that some or all of these features may be combined with any one of the aspects and remain within the scope of the invention. Accordingly, the present invention is not to be restricted except in light of the attached claims and their equivalents.