Method of manufacturing variable vane seal and washer materials

• US 6,915,574 B2
• Filed: 03/29/2001
• Issued: 07/12/2005
• Est. Priority Date: 01/29/1999
• Status: Expired due to Fees

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: Mesing, Thomas C., Hester, David B., Bowen, Wayne R.
• Primary Examiner(s): Bryant, David P.
• Assistant Examiner(s): COMPTON, ERIC B
• Application Number:
  US09/821,570
• Publication Number:
  US 20010016091A1
• Time in Patent Office: 1,566 Days
• Field of Search: 298/980.54, 298/980.55, 298/98, 298/981.5, 298/981, 298/883, 384/298, 384/300, 384/908, 384/911, 428/549, 428/550, 428/551, 508/104, 508/105, 191/44, 191/45
• US Class Current: 29/898.055
• CPC Class Codes: F01D 17/162 for axial flow, i.e. the vanes turning around axes which are essentially perpendicular to the rotor centre line F01D17/167 takes precedence
• CPC Class Codes: F04D 29/023 especially adapted for elastic fluid pumps
• CPC Class Codes: F04D 29/083 especially adapted for elastic fluid pumps
• CPC Class Codes: F05D 2230/31 Layer deposition
• CPC Class Codes: F05D 2300/432 PTFE [PolyTetraFluorEthylene]
• CPC Class Codes: F05D 2300/434 Polyimides, e.g. AURUM
• CPC Class Codes: F05D 2300/603 Composites; e.g. fibre-reinforced
• CPC Class Codes: Y10S 384/908 Nylon or polytetrafluorethylene
• CPC Class Codes: Y10S 384/911 including fiber
• CPC Class Codes: Y10T 29/49297 Seal or packing making
• CPC Class Codes: Y10T 29/49668 Sleeve or bushing making
• CPC Class Codes: Y10T 29/4967 Nonmetallic
• CPC Class Codes: Y10T 29/49702 Lubricating
• CPC Class Codes: Y10T 428/12035 Fiber, asbestos, or cellulose in or next to particulate component
• CPC Class Codes: Y10T 428/12049 Nonmetal component

Abstract

A multi-layer seal and washer that provide a seal between a vane stem and a casing in a turbine engine are disclosed. The seal and washer are fabricated from materials such as Teflon fibers and glass fibers and are impregnated with a polyimide resin. The seal and washer are durable and have a low coefficient of friction.

Claims

1. A method for manufacturing a bearing element comprising the steps of:

forming a plurality of layers from a combination of a first material and a second material, wherein a first of the layers includes an exterior surface and an interior surface, the first layer formed from a plurality of materials comprising polytetrafluoroethylene fibers, and at least one of glass fibers and carbon fibers, wherein the exterior surface includes a higher concentration of polytetrafluoroethylene fibers and the interior surface includes a higher concentration of the at least one of glass fibers and carbon fibers, and wherein a second of the layers is formed against the first layer and is formed from a material comprising at least one of glass fibers and carbon fibers, and wherein a third of the layers includes an exterior surface and an interior surface, the first layer formed from a plurality of materials comprising polytetrafluoroethylene fibers, and at least one of glass fibers and carbon fibers, wherein the exterior surface includes a higher concentration of polytetrafluoroethylene fibers and the interior surface includes a higher concentration of the at least one of glass fibers and carbon fibers;

forming the bearing element from the plurality of layers, wherein each layer is formed from at least one of weaving materials and braiding materials;

plasma etching each of the bearing element plurality of layers to facilitate enhancing bonding between adjacent layers; and

impregnating each of the bearing element plurality of layers with a polyimide resin comprising polytetrafluoroethylene powder.

2. A method in accordance with claim 1 wherein said step of forming the plurality of layers further comprises the steps of:

forming the first layer from a woven mat of the first material;

forming the second layer from a woven mat of the second material; and

forming the third layer from a woven mat of the first material.

3. A method in accordance with claim 1 wherein said step of forming the plurality of layers further comprises the steps of:

forming the first layer from a braid of the first material;

forming the second layer from a braid of the second material; and

forming the third layer from a braid of the first material.

4. A method in accordance with claim 1 wherein:

the first layer comprises polytetrafluoroethylene fibers and glass fibers;

the second layer comprises glass fibers;

the third layer comprises polytetrafluoroethylene fibers and glass fibers; and

the glass fibers are coated with an epoxy sizing.

5. A method in accordance with claim 4 wherein carbon fibers are substituted for the glass fibers.

6. A method in accordance with claim 4 wherein quartz fibers are substituted for the glass fibers.

7. A method in accordance with claim 4 wherein a silane sizing is substituted for the epoxy sizing.