Abstract: A method of manufacturing gas and/or fuel swirlers for fuel injectors and combustor domes and cone-shaped swirlers so manufactured are disclosed. The disclosed conical swirlers feature cut-through slots on a cone-shaped body. The contour and spacing of the slots are configured and arranged to accommodate a wide range of requirements for fluid flow areas and swirl strengths. Preferably, the cone-shaped swirlers can be manufactured by wire EDM processing. More preferably, multiple cone-shaped swirlers can be manufactured simultaneously by nesting wirier blanks in a stack and wire EDM processing the stack as a unit. The cone-shaped pinwheel swirler fits well into various fuel injector heads, enabling the injectors to reduce the frontal surface area and flat area for minimal potential of carbon formation.

Abstract: A method of manufacturing gas and/or fuel swirlers for fuel injectors and combustor domes and cone-shaped swirlers so manufactured are disclosed. The disclosed conical swirlers feature cut-through slots on a cone-shaped body. The contour and spacing of the slots are configured and arranged to accommodate a wide range of requirements for fluid flow areas and swirl strengths. Preferably, the cone-shaped swirlers can be manufactured by wire EDM processing. More preferably, multiple cone-shaped swirlers can be manufactured simultaneously by nesting wirier blanks in a stack and wire EDM processing the stack as a unit. The cone-shaped pinwheel swirler fits well into various fuel injector heads, enabling the injectors to reduce the frontal surface area and flat area for minimal potential of carbon formation.

Abstract: A method of manufacturing gas and/or fuel swirlers for fuel injectors and combustor domes and cone-shaped swirlers so manufactured are disclosed. The disclosed conical swirlers feature cut-through slots on a cone-shaped body. The contour and spacing of the slots are configured and arranged to accommodate a wide range of requirements for fluid flow areas and swirl strengths. Preferably, the cone-shaped swirlers can be manufactured by wire EDM processing. More preferably, multiple cone-shaped swirlers can be manufactured simultaneously by nesting swirler blanks in a stack and wire EDM processing the stack as a unit. The cone-shaped pinwheel swirler fits well into various fuel injector heads, enabling the injectors to reduce the frontal surface area and flat area for minimal potential of carbon formation.

Abstract: A fuel injection and mixing system is provided that is suitable for use with various types of fuel reformers. Preferably, the system includes a piezoelectric injector for delivering atomized fuel, a gas swirler, such as a steam swirler and/or an air swirler, a mixing chamber and a flow mixing device. The system utilizes ultrasonic vibrations to achieve fuel atomization. The fuel injection and mixing system can be used with a variety of fuel reformers and fuel cells, such as SOFC fuel cells.

Abstract: A fuel injector for a gas turbine engine is disclosed that includes an injector body having a bore, a fitting at an inlet end of the injector body for receiving fuel, an atomizer at an outlet end of the injector body for delivering atomized fuel to a combustor of the gas turbine engine, a fuel tube disposed within the bore of the injector body for delivering fuel from the fitting to the atomizer, the fuel tube having an inlet end portion adjacent the fitting and an outlet end portion joined to the atomizer, and structure joined to the inlet end portion of the fuel tube to compensate for thermal growth of the injector body relative to the fuel tube during engine operation.

Abstract: A fuel injection and mixing system is provided. The system includes an injector body having a fuel inlet and a fuel outlet, and defines a fuel flow path between the inlet and outlet. The fuel flow path may include a generally helical flow passage having an inlet end portion disposed proximate the fuel inlet of the injector body. The flow path also may include an expansion chamber downstream from and in fluid communication with the helical flow passage, as well as a fuel delivery device in fluid communication with the expansion chamber for delivering fuel. Heating means is also provided in thermal communication with the injector body. The heating means may be adapted and configured for maintaining the injector body at a predetermined temperature to heat fuel traversing the flow path. A method of preheating and delivering fuel is also provided.

Abstract: Systems and methods for injecting and mixing a liquid hydrocarbon fuel to provide a uniform, homogenous fuel vapor mixture for introduction into a fuel reformer for use with a fuel cell are disclosed. Preferably, the system includes a fuel injector that generates and aspirate a liquid fuel in the presence of an atomizing gas stream; a diverging-converging mixing chamber, into which the atomized fuel and a secondary fluid stream are introduced, to enhance the mixing of the fuel and the added heated gas or steam; and a mixer/swirler, which can be centrally located in the mixing chamber between the upper and lower chambers, to stabilize the fuel vapor mixture further for greater uniformity and homogeneity. More preferably, grooves and/or brazed wires can be provided on the surfaces of the mixing chamber and/or mixer/swirler to channel any accumulated fuel so as to provide sufficient time to evaporate the accumulated fuel.

Abstract: Systems and methods for injecting and mixing a liquid hydrocarbon fuel to provide a uniform, homogenous fuel vapor mixture for introduction into a fuel reformer for use with a fuel cell are disclosed. Preferably, the system comprises a fuel injector that generates and aspirate a liquid fuel in the presence of an atomizing gas stream; a diverging-converging mixing chamber, into which the atomized fuel and a secondary fluid stream are introduced, to enhance the mixing of the fuel and the added heated gas or steam; and a mixer/swirler, which can be centrally located in the mixing chamber between the upper and lower chambers, to stabilize the fuel vapor mixture further for greater uniformity and homogeneity. More preferably, grooves and/or brazed wires can be provided on the surfaces of the mixing chamber and/or mixer/swirler to channel any accumulated fuel so as to provide sufficient time to evaporate the accumulated fuel.

Abstract: A fuel injection and mixing system is provided that is suitable for use with various types of fuel reformers. Preferably, the system includes a piezoelectric injector for delivering atomized fuel, a gas swirler, such as a steam swirler and/or an air swirler, a mixing chamber and a flow mixing device. The system utilizes ultrasonic vibrations to achieve fuel atomization. The fuel injection and mixing system can be used with a variety of fuel reformers and fuel cells, such as SOFC fuel cells.

Abstract: A fuel injector for a gas turbine engine is disclosed that includes an injector body having a bore, a fitting at an inlet end of the injector body for receiving fuel, an atomizer at an outlet end of the injector body for delivering atomized fuel to a combustor of the gas turbine engine, a fuel tube disposed within the bore of the injector body for delivering fuel from the fitting to the atomizer, the fuel tube having an inlet end portion adjacent the fitting and an outlet end portion joined to the atomizer, and structure joined to the inlet end portion of the fuel tube to compensate for thermal growth of the injector body relative to the fuel tube during engine operation.

Abstract: A fuel injection and mixing system is provided. The system includes an injector body having a fuel inlet and a fuel outlet, and defines a fuel flow path between the inlet and outlet. The fuel flow path may include a generally helical flow passage having an inlet end portion disposed proximate the fuel inlet of the injector body. The flow path also may include an expansion chamber downstream from and in fluid communication with the helical flow passage, as well as a fuel delivery device in fluid communication with the expansion chamber for delivering fuel. Heating means is also provided in thermal communication with the injector body. The heating means may be adapted and configured for maintaining the injector body at a predetermined temperature to heat fuel traversing the flow path. A method of preheating and delivering fuel is also provided.

Abstract: A method of manufacturing gas and/or fuel swirlers for fuel injectors and combustor domes and cone-shaped swirlers so manufactured are disclosed. The disclosed conical swirlers feature cut-through slots on a cone-shaped body. The contour and spacing of the slots are configured and arranged to accommodate a wide range of requirements for fluid flow areas and swirl strengths. Preferably, the cone-shaped swirlers can be manufactured by wire EDM processing. More preferably, multiple cone-shaped swirlers can be manufactured simultaneously by nesting swirler blanks in a stack and wire EDM processing the stack as a unit. The cone-shaped pinwheel swirler fits well into various fuel injector heads, enabling the injectors to reduce the frontal surface area and flat area for minimal potential of carbon formation.

Abstract: An atomizer including a fuel output portion shaped to provide a fuel output and an air swirler portion shaped to direct streams of air at the fuel. The air swirler portion includes an outer opening and an inner opening located radially inwardly relative to the outer opening. The inner and outer openings are arranged such that an air stream passed through the inner opening does not intersect a conical section defined by an air stream passed through the outer opening unless both of said air streams are moving at least partially radially outwardly.

Abstract: A multiplex injector system comprising an injector head, a first fuel path located in the injector head, and a first set of injector tips located in the injector head and in fluid communication with the first fuel path. The first set of injector tips includes at least one first injector tip. The multiplex injector further includes a second fuel path located in the injector head and a second set of injector tips located in the injector head and in fluid communication with the second fuel path. The second set of injector tips includes at least one second injector tip. A flow of fuel in each of the first and second fuel paths can be selectively controlled to control the flow of fuel through the first and second sets of injector tips.

Abstract: An atomizer including a fuel output portion shaped to provide a fuel output and an air swirler portion shaped to direct streams of air at the fuel. The air swirler portion includes an outer opening and an inner opening located radially inwardly relative to the outer opening. The inner and outer openings are arranged such that an air stream passed through the inner opening does not intersect a conical section defined by an air stream passed through the outer opening unless both of said air streams are moving at least partially radially outwardly.

Abstract: A coating formulation for application to surfaces associated with combustion, such as fuel injectors, and surfaces subjected to elevated temperatures, such as fuel supply components, to prevent the deposition at high temperatures of carbon or graphite on such surfaces, such as stainless steel and alloyed steel compositions. The coating formulation forms a thin layer of polymer coating on the surface by chemical grafting involving the use of a graft initiator to create active bonding sites, on the metal surface, for the silicone-based prepolymer to undergo polymerization on the metal surface. The bonding and polymerization are completed in a single application process without using complex equipment. The coating and process helps surfaces associated with combustion and surfaces subjected to elevated temperature reduce carbon or coke formation at temperatures up to 700° F. and thereby improves the durability and performance of those surfaces.

Abstract: A spray nozzle designed to produce a spray or mist containing a high concentration of bubbles. Such a spray is particularly useful in mixing liquid fuel and air for burning within a combustion chamber, as for example in a gas turbine engine. The novel design includes a pair of swirl chambers generally axially aligned within the nozzle. Fuel or other liquid enters the first or forward swirl chamber in a generally tangential and laminar flow pattern, passes into the second or rearward chamber through an interconnecting orifice. Violent liquid and air mixing occurs in the second chamber and the mixture is then expelled as an aerated spray through the interconnecting orifice, the first chamber and a discharge orifice.