[0001] The present invention relates to seals for sealing a circumferential gap between two machine components that are relatively rotatable with respect to each other, and, more particularly, to a seal having at least one shoe extending along one of the machine components in a position to create a non-contact seal therewith.

2. Description of the Related Art

[0002] Turbomachinery, such as gas turbine engines, currently is dependent on either labyrinth, brush or carbon seals for critical applications. Labyrinth seals provide adequate sealing, but they are extremely dependent on maintaining radial tolerances at all points of engine operation. The radial clearance must take into account factors such as thermal expansion, shaft motion, tolerance stack-ups, rub tolerance, etc. Minimization of seal clearance is necessary to achieve maximum labyrinth seal effectiveness. In addition to increased leakage if clearances are not maintained, there is the potential for increases in engine vibration. Straight-thru labyrinth seals are the most sensitive to clearance changes, with large clearances resulting in a carryover effect. Stepped labyrinth seals are very dependent on axial clearances, as well as radial clearances, which limits the number of teeth possible on each land. Pregrooved labyrinth seals are dependent on both axial and radial clearances, and must have an axial clearance less than twice the radial clearance to provide better leakage performance than stepped seals.

[0003] Turbomachinery, such as gas turbines engines, are becoming larger, more efficient, and more robust. Large blades and vanes are being utilized, especially in the hot section of the engine system. In view of high pressure ratios and high engine firing temperatures implemented in modem engines, certain components, such as airfoils, e.g., stationary vanes and rotating blades, require more efficient sealing capabilities than the ones that exist currently.

[0004] In current assemblies, clearance between the rotating and stationary components in turbomachinery are regions of low performance. There are several drivers of aerodynamic loss in the compressor- vane carrier, turbine-shroud cavity configuration, intermediate shaft, and the like, which lowers the turbomachinery’s efficiency. One driver is the flow over the rotating components. The mixing losses that occur downstream of clearance areas are high and contribute to a reduction in stage efficiency and power. Additional mixing losses occur when the flow through the tip cavity combines with the main flow and the two streams have different velocities. Tip leakage is essentially lost opportunity for work extraction. Tip leakage also contributes towards aerodynamic secondary losses.

SUMMARY

[0005] In an aspect of the present invention, a seal assembly for sealing a circumferential gap between a first machine component and a second machine component which is rotatable relative to the first machine component about a longitudinal axis in the axial direction, comprising: a seal carrier plate that surrounds the components of the seal assembly radially together along an outer ring on each axial end of the seal assembly, wherein the seal carrier plate comprises an inner surface that has an arm shaped carve out portion; a primary seal comprising: at least one shoe extending along one of the first and second machine components, producing a non-contact seal therewith, the shoe being formed with a slot; at least one spring element adapted to connect to one of the first and second machine components and being connected to the at least one shoe, the at least one spring element being effective to deflect and move with the at least one shoe in response to fluid pressure applied to the at least one shoe by a fluid stream to assist in the creation of a primary seal of the circumferential gap between the first and second machine components; wherein an outer radial end of the primary seal extends into the arm shaped carve out portion forming a mechanical fit with the seal carrier plate; a mid plate comprising a groove, the mid plate extending into the slot formed in the at least one shoe; and at least one secondary seal comprising at least one sealing element oriented side-by-side, the at least one sealing element are flush into the groove of the mid plate and extend into the slot formed in the at least one shoe, sealing the at least one spring element in the axial direction.

[0006] These and other features, aspects, and advantages of the present invention will become better understood with reference to the following drawings, description, and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The invention is shown in more detail by help of figures. The figures show preferred configurations and do not limit the scope of the invention.

[0008] FIG. 1 is an exploded view of a seal assembly in the prior art;

[0009] FIG. 2 is an end view of an assembled seal assembly in the prior art;

[0010] FIG. 3 is an elevational view of a portion of a prior art seal assembly;

[0011] FIG. 4 is an elevational view of a portion of an exemplary embodiment of the present invention;

[0012] FIG. 5 is an elevational view of a portion of an exemplary embodiment of the present invention;

[0013] FIG. 6 is an elevational view of a portion of a prior art seal assembly;

[0014] FIG. 7 is an elevational view of a portion of a prior art seal assembly;

[0015] FIG. 8 is an end view of an assembled seal assembly of an exemplary embodiment of the present invention;

[0016] FIG. 9 is an end view of a portion of an assembled seal assembly of an exemplary embodiment of the present invention; and

[0017] FIG. 10 is an end view of an assembled seal assembly of an exemplary embodiment of the present invention.

DETAILED DESCRIPTION [0018] In the following detailed description of the preferred embodiment, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration, and not by way of limitation, a specific embodiment in which the invention may be practiced. It is to be understood that other embodiments may be utilized, and that changes may be made without departing from the spirit and scope of the present invention.

[0019] Broadly, an embodiment of the present invention provides a seal assembly for sealing a circumferential gap between a first machine component and a second machine component which is rotatable relative to the first machine component about a longitudinal axis. The seal assembly includes a seal carrier plate, a primary seal, a mid plate, and at least one secondary seal. The seal carrier plate surrounds the primary seal, mid plate, and the secondary seal radially along an outer ring on each axial end of the seal assembly. The at least one secondary seal includes at least one sealing element. An outer radial end of the primary seal extends into the seal carrier plate forming a mechanical fit.

[0020] Turbomachinery typically includes a compressor section, a combustor, and a turbine section. The compressor section ingests ambient air and compresses it. The compressed air from the compressor section enters one or more combustors in the combustor section. The compressed air is mixed with fuel in the combustors, and an air- fuel mixture is combusted in the combustors to form a hot working gas. The hot working gas is routed to the turbine section, where it is expanded through alternating rows of stationary airfoils and rotating airfoils, and used to generate power that can drive a rotor. The expanded gas exiting the turbine section then exhausts from the engine via an exhaust section. [0021] The compressor and turbine sections may include several locations in which there may be gaps, or clearances, between the rotating and stationary components.

During engine operation, system loss may occur through fluid leakage through clearances in the compressor and turbine sections. This system loss decreases the operational efficiency of the system. An example of the flow leakage is across a clearance between the tips of rotating blades and a surrounding stationary structure or boundary, such as an outer shroud or a vane carrier.

[0022] Seals are necessary to prevent leakage across areas within the gas turbine engine. Traditionally, a non-contact seal does not retain secondary seals well within the seal assembly. A non-contact seal with better support and retainment of components of the seal assembly is desired.

[0023] FIG. 1 shows an exploded view of a seal assembly 10 that may be included in turbomachinery, such as a gas turbine. FIG. 2 shows the seal assembly 10 in its assembled form. The seal assembly 10 may include a front plate 12, at least one secondary seal 14, a mid plate 22, a primary seal 26, and a seal carrier 36. The assembled seal assembly 10 illustrated in FIG. 2 creates a non-contact seal of a circumferential gap 11 between two components, a first machine component 38 and a second machine component 40, such as a fixed stator 72 and a rotating rotor 48.

[0024] Each seal assembly 10 includes at least one, and in some situations, a plurality of circumferentially spaced shoes 28 that are located in a non-contact position along an exterior surface of the rotor 48, as part of the primary seal 26. Each shoe 28 has a sealing surface 70 and a slot 30 that extends radially inward toward the sealing surface 70 as can be seen in FIG. 1. The at least one shoe 28 is formed with two or more projections 78, or fins, relative to one of the machine components, and is the bottom portion of the primary seal 26, as can be seen in FIG. 6. For purposes of this discussion, the term“axial” or “axially spaced” refers to a direction along the longitudinal axis 42 of the stator 72 and rotor 48, whereas“radial” refers to a direction perpendicular to the longitudinal axis 42. The seal assembly 10 may extend along a circumferential direction C relative to the turbine longitudinal axis 42.

[0025] In certain operating conditions, especially at higher pressures, it is desirable to limit the extent of radial movement of the shoes 28 with respect to the rotor 48 to maintain clearances, e.g. the spacing between the shoes 28, and the facing surface of the rotor 48. The primary seal 26 may include a number of circumferentially spaced spring elements, or at least one spring element 34, as can be better seen in FIG. 6. Each spring element 34 is formed with an inner band 52, and an outer band 54 radially outwardly spaced from the inner band 52. One end of each of the bands 52 and 54 is mounted to, or integrally formed with, the stator 72 and the opposite end thereof is connected to a first stop 32. The first stop 32 includes a leg 56 which is connected to, or integrally formed with a shoe 28, and an arm 58 opposite to the shoe 28, which may be received within a recess formed in the stator 72. The recess has a shoulder 74 positioned in alignment with the arm 58 of the first stop 32.

[0026] A second stop 60 is connected to, or integrally formed with, the shoe 28. The second stop 60 is circumferentially spaced from the first stop 32 in a position near the point at which the inner and outer bands 52 and 54 connect to the stator 72. The second stop 60 is formed with a leg 62 and an arm 64. The arm 64 may be received within a recess in the stator 72. The recess has a shoulder 74 positioned in alignment with the arm 64 of the second stop 60.

[0027] In certain situations, when seal assembly embodiments are used in applications such as gas turbine engines, aerodynamic forces are developed that can apply a fluid pressure to the shoe 28, causing it to move radially inwardly toward the rotor 48. The spring elements 34 deflect and move with the shoe 28, to create a primary seal of the circumferential gap 11 between the rotor 48 and stator 72, for instance. The first and second stops 32 and 60 can limit the extent of radially inward and outward movement of the shoe 28, with respect to the rotor 48 in the radial direction R. A gap is provided between the arm 58 of the first stop 32, and the shoulder, and between the arm 64 of the second stop 60, and the shoulder, such that the shoe 28 can move radially inwardly relative to the rotor 48. The inward motion mentioned above is limited by engagement of the arms with the shoulders to prevent the shoe 28 from contacting the rotor 48, or exceeding design tolerances for the gap between the two. The arms can also contact the carrier 36 in the event that the shoe 28 moves radially outwardly relative to the rotor 48, to limit movement of the shoe 28 in that direction.

[0028] The seal assembly 10 includes at least one secondary seal 14 that includes at least one sealing element 16, or plate. At least one spring member 18 can be positioned radially outward from the plate, as is shown in FIG. 4, along an outer ring surface 20. In certain embodiments, the at least one sealing element 16 includes two sealing elements 16 oriented side-by-side in the axial direction A and positioned so that the plate segments extend into the slot 30 of the at least one shoe 28. The at least one sealing element 16 help to radially deflect and move with the at least one shoe 28, in response to the application of fluid pressure to the at least one shoe 28, in a way that assists in the creation of a secondary seal 14 of the circumferential gap 11 between the first and second machine components 38 and 40. In certain embodiments, the at least one secondary seal 14 includes an aft secondary seal and a forward secondary seal that may be identical and reversed at assembly.

[0029] FIG. 5 shows a mid plate 22. The mid plate 22 includes at least one groove 24 along a face of the mid plate 22 that extends into the slot 30 formed in the at least one shoe 28, and is positioned between the at least one secondary seal 14 and the at least one shoe 28 of the primary seal 26. The sealing elements 16 of the at least one secondary seal 14 fits into the groove 24 of the mid plate 22.

[0030] FIG. 3 shows a front plate 12 used in the prior art. The front plate 12 can be used to cover the components of the seal assembly 10 in the axial direction A. The seal assembly 10 may include having the at least one secondary seal 14 positioned between the front plate 12 and the mid plate 22. The primary seal 26 may support the inner diameter of the secondary seal 14, and the mid plate 22 can support the outer diameter of the secondary seal 14. During operation, the spring member 18 of the secondary seal 14 may react against the mid plate 22.

[0031] FIG. 7 shows a seal carrier 36 of the prior art. The seal carrier 36 holds all the components of the seal assembly 10 together along a radially outward position of a radially outer ring 50 of the seal carrier 36. In certain embodiments, along the radially outward surface of the primary seal 26, the mid plate 22, and the front plate 12, there may be a cutout 66. The seal carrier 36, has a protruding edge 68 that extends radially inward that aligns with the cutouts 66 of the other components to help the components to align in the relative area.

[0032] Traditionally, the seal carrier 36 is laser welded to bond to the front plate 12. Welding of these parts causes dimensional distortion of the fully assembled part. Further, welding adds design risk due to higher probability that failure initiation (i.e. crack initiation) is more likely to occur in a weld zone or heat affected zone.

[0033] FIG. 8 through 10 show embodiments, or portions of embodiments, of a new seal assembly 86 that provides an alternative to a final welding at assembly. The seal assembly 86 includes a seal carrier plate 80 that surrounds the components of the seal assembly 86 radially together along an outer ring 50 on each axial end of the seal assembly 86. The seal carrier plate 80 includes an inner surface 94 that has an arm shaped carve out portion 96. The seal assembly 86 also includes a primary seal 82 that includes the least one shoe 28 that extends along one of the first and second machine components 38, 40. The at least one shoe 28 helps to produce a non-contact seal therewith. The at least one shoe 28 includes the slot 30. The primary seal 82 also includes at least one spring element 34 adapted to connect to one of the first and second machine components 38, 40, and also connected to the at least one shoe 28. The at least one spring element 34 deflects and moves with the at least one shoe 28 in response to fluid pressure applied to the at least one shoe 28 by a fluid stream to assist in the creation of a primary seal of the circumferential gap 11 between the first and second machine components 38, 40. An outer radial end 92 of the primary seal 82 extends into the arm shaped carve out portion 96 of the seal carrier plate 80 forming a mechanical fit 84 with the seal carrier plate 80.

[0034] A mid plate 22 that includes a groove 24 extends into the slot 30 formed in the at least one shoe 28 of the primary seal 82. At least one secondary seal 14 includes at least one sealing element 16. In certain embodiments, there are two sealing elements 16 that are oriented side-by-side in the axial direction A. Each of the at least one sealing element 16 can include at least one spring member 18 mounted along an outer ring surface 20 of the at least one sealing element 16. The at least one sealing element 16 is placed flush into the groove 24 of the mid plate 22 and extend into the slot 30 formed in the at least one shoe 28. The secondary seal 14 helps to seal the at least one spring element 34 in the axial direction A.

[0035] The weld process mentioned above, and the inspection process, can be eliminated to streamline the manufacturing processes and reduce part count. As part of the manufacturing process of the new seal assembly 86, waxing of the secondary seal 14 and the mid plate 22 to the primary seal 82 can occur. The waxing of these components allows for the primary seal 82, the mid plate 22, and the secondary seals 14 to be rolled into the seal carrier plate 80 as an assembly, and to complete the mechanical fit 84. The mechanical fit 84 can be adjusted should the need arise by adjusting the machining tolerances. A mechanical fit can be controlled before final assembly, and achieve less distortion at final assembly, and thus can achieve less leakage. [0036] While specific embodiments have been described in detail, those with ordinary skill in the art will appreciate that various modifications and alternative to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the invention, which is to be given the full breadth of the appended claims, and any and all equivalents thereof.