airfoil components of a gas turbine engine

Abstract

In one exemplary embodiment of this disclosure, an airfoil for a gas turbine engine is provided. The airfoil defines a spanwise direction, a root end, and a tip end. The airfoil includes: a body defining a pressure side and a suction side and extending in the spanwise direction between the root end and the tip end, the body being formed of a composite material; and a sparsity surrounding the airfoil body and extending in the spanwise direction, the sparsity including a plurality of sparsity segments arranged in an overlapping configuration in the spanwise direction.

Description

Technical Field

[0001] This disclosure relates to an airfoil for a gas turbine engine. Background Technology

[0002] Gas turbine engines typically include a turbine and a rotor assembly. Gas turbine engines, such as turbofan engines, are used for aircraft propulsion. In the case of a turbofan engine, the rotor assembly can be configured as a fan assembly. The turbine may include a spool arrangement. For example, the spool arrangement may include a high-pressure, high-speed spool and a low-pressure, low-speed spool. The combustion section of the turbine receives pressurized air, which is mixed with fuel and burned in the combustion chamber to produce combustion gases. These combustion gases are supplied to the spool arrangement. For example, the combustion gases may first be supplied to a high-pressure turbine on the high-pressure spool, driving the high-pressure spool, and then supplied to a low-speed turbine on the low-speed spool, driving the low-speed spool.

[0003] In a turbofan engine, the fan assembly typically includes a fan having multiple airfoils or fan blades extending radially outward from a central hub and / or disk. During certain operations, the fan blades provide airflow into and above the turbine to generate thrust.

[0004] At least some modern fan blades are made of composite materials to reduce their weight. Composite fan blades can be affected by foreign object ingestion events, such as ice ingestion or bird strikes. Airfoil design improvements designed to withstand these events would be welcome in this field. Summary of the Invention

[0005] Aspects and advantages of the invention will be set forth in part in the description which follows, or may be apparent from the description, or may be learned by practice of the invention.

[0006] In one exemplary embodiment of this disclosure, an airfoil is provided. The airfoil defines a spanwise direction, a root end, and a tip end. The airfoil includes: a body defining a pressure side and a suction side and extending in the spanwise direction between the root end and the tip end, the body being formed of a composite material; and a sparsity surrounding the airfoil body and extending in the spanwise direction, the sparsity including a plurality of sparsity segments arranged in an overlapping configuration in the spanwise direction.

[0007] These and other features, aspects, and advantages of the invention will be better understood by reference to the following description and the appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention. Attached Figure Description

[0008] The complete and effective disclosure of the invention, including its best mode, to those skilled in the art is set forth in the description with reference to the accompanying drawings, wherein:

[0009] Figure 1 This is a cross-sectional view of a gas turbine engine according to an exemplary aspect of this disclosure.

[0010] Figure 2 This is a perspective view of a fan assembly for a gas turbine engine according to an exemplary aspect of this disclosure.

[0011] Figure 3 This is a perspective view of a fan blade for a gas turbine engine according to an exemplary aspect of this disclosure.

[0012] Figure 4 This is a cross-sectional view of an airfoil for a gas turbine engine according to an exemplary aspect of this disclosure.

[0013] Figure 5 Based on exemplary aspects of this disclosure Figure 4 A cross-sectional view of the spar of an exemplary airfoil.

[0014] Figure 6 Based on exemplary aspects of this disclosure Figure 4 A close-up cross-sectional view of the spar of an exemplary airfoil.

[0015] Figure 7 This is a cross-sectional view of an airfoil for a gas turbine engine according to another exemplary aspect of this disclosure.

[0016] Figure 8 This is a cross-sectional view of an airfoil for a gas turbine engine according to yet another exemplary aspect of this disclosure. Detailed Implementation

[0017] Reference will now be made in detail to the present embodiments of the invention, one or more examples of which are illustrated in the accompanying drawings. Detailed descriptions use numbers and letters to designate features in the drawings. The same or similar reference numerals in the drawings and description have been used to designate the same or similar portions of the invention.

[0018] The word "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any implementation described herein as "exemplary" is not necessarily to be construed as superior to or better than other implementations. Furthermore, unless explicitly stated otherwise, all embodiments described herein should be considered exemplary.

[0019] As used herein, the terms “first,” “second,” and “third” are used interchangeably to distinguish one component from another and are not intended to indicate the location or importance of the components.

[0020] The terms "front" and "rear" refer to relative positions within a gas turbine engine or vehicle, and specifically to the normal operating posture of the gas turbine engine or vehicle. For example, for a gas turbine engine, "front" refers to the position closer to the engine inlet, while "rear" refers to the position closer to the engine nozzle or exhaust port.

[0021] The terms "upstream" and "downstream" refer to the relative directions of fluid flow within a fluid path. For example, "upstream" refers to the direction in which the fluid flows from, and "downstream" refers to the direction in which the fluid flows to.

[0022] The terms “connection,” “fixation,” “attachment,” etc., refer to both direct connection, fixation, or attachment, and indirect connection, fixation, or attachment through one or more intermediate components or features, unless otherwise stated herein.

[0023] The singular forms “a,” “one,” and “the” include plural references unless the context clearly indicates otherwise.

[0024] The approximate language used throughout the specification and claims is applied to modify any quantitative expression that allows for variation without altering its associated essential function. Therefore, values ​​modified by one or more terms such as “about,” “approximately,” and “substantially” are not limited to specified exact values. In at least some cases, approximate language may correspond to the precision of the instrument used to measure the value, or the precision of the method or machine used to construct or manufacture the component and / or system. For example, approximate language may refer to a range of 1%, 2%, 4%, 10%, 15%, or 20%. These approximate margins may apply to a single value, define one or both endpoints of a numerical range, and / or the margin of the range between the endpoints.

[0025] Throughout this specification and claims, scope limitations are combined and interchanged, and such scopes are identified and include all subscopes contained herein, unless the context or language otherwise indicates. For example, all scopes disclosed herein include endpoints, and endpoints may be combined independently of each other.

[0026] This disclosure generally relates to an airfoil for a gas turbine engine, such as a fan blade for a fan assembly in a turbofan engine or turboprop engine. The airfoil can typically be formed of a composite material and may include one or more reinforcing members. The reinforcing members are connected in a manner that defines a failure point for the airfoil, such that in the event of foreign object ingestion, the airfoil will fail at one of these failure points, thereby damaging only a portion of the airfoil rather than the entire airfoil.

[0027] In particular, the airfoil element disclosed herein typically includes a composite body portion and a spars enclosing the composite body portion. The spars are segmented spars having multiple spars segments joined together at joints. The spars may be weaker at the joints, allowing the airfoil element to fail at these joints.

[0028] Referring now to the accompanying drawings, where the same numbers indicate the same elements throughout all the drawings. Figure 1 This is a schematic cross-sectional view of a gas turbine engine according to exemplary embodiments of the present disclosure. More specifically, for Figure 1 In one embodiment, the gas turbine engine is a high-bypass turbofan jet engine, referred to herein as "turbofan engine 10". Figure 1 As shown, the turbofan engine 10 defines an axial direction A (extending parallel to the longitudinal centerline 12 provided for reference), a radial direction R, and a circumferential direction C (see...). Figure 2 Typically, the turbofan 10 includes a fan section 14 and a turbine 16 disposed downstream of the fan section 14.

[0029] The depicted exemplary turbine 16 typically includes a generally tubular housing 18 defining an annular inlet 20. The housing 18 surrounds, in a series flow relationship: a compressor section including a boost or low-pressure (LP) compressor 22 and a high-pressure (HP) compressor 24; a combustion section 26; a turbine section including a high-pressure (HP) turbine 28 and a low-pressure (LP) turbine 30; and an exhaust nozzle section 32. A high-pressure (HP) shaft or spool 34 drives the HP turbine 28 to the HP compressor 24. A low-pressure (LP) shaft or spool 36 drives the LP turbine 30 to the LP compressor 22. The compressor section, combustion section 26, turbine section, and nozzle section 32 together define a core airflow path 37.

[0030] For the depicted embodiment, fan section 14 includes a fan 38 having a plurality of fan blades 40 spaced apart and coupled to rotor disk 42. As shown, the fan blades 40 generally extend radially outward from rotor disk 42. Disk 42 is covered by a rotatable front hub 48 having an aerodynamic profile to facilitate airflow through the plurality of fan blades 40. Furthermore, the exemplary fan section 14 includes an annular fan housing or outer nacelle 50 circumferentially surrounding at least a portion of the fan 38 and / or turbine 16. It should be understood that the nacelle 50 may be configured to be supported relative to the core 16 by a plurality of circumferentially spaced outlet guide vanes 52. Additionally, a downstream section 54 of the nacelle 50 may extend externally to the turbine 16 to define a bypass airflow passage 56 therebetween.

[0031] During operation of the turbofan engine 10, a volume of air 58 enters the turbofan 10 through the nacelle 50 and / or the relevant inlet 60 of the fan section 14. As the volume of air 58 passes through the fan blades 40, a first portion of the air 58, as indicated by arrow 62, is directed or directed into the bypass airflow passage 56, and a second portion of the air 58, as indicated by arrow 64, is directed or directed into the core airflow path 37, or more specifically, into the LP compressor 22. The ratio between the first portion of air 62 and the second portion of air 64 is commonly referred to as the bypass ratio. The pressure of the second portion of air 64 then increases as it passes through the HP compressor 24 and enters the combustion section 26, where it mixes with fuel and burns to provide combustion gases 66.

[0032] Combustion gas 66 is guided through HP turbine 28, where a portion of the thermal and / or kinetic energy from the combustion gas 66 is extracted through a sequential stage of HP turbine stator blades 68 connected to housing 18 and turbine rotor blades 70 connected to HP shaft or spool 34, thereby rotating HP shaft or spool 34 to support the operation of HP compressor 24. Combustion gas 66 is then guided through LP turbine 30, where a second portion of the thermal and kinetic energy is extracted from the combustion gas 66 through a sequential stage of LP turbine stator blades 72 connected to housing 18 and LP turbine rotor blades 74 connected to LP shaft or spool 36, thereby rotating LP shaft or spool 36 to support the operation of LP compressor 22 and / or the rotation of fan 38.

[0033] Combustion gas 66 is then directed through the injection exhaust nozzle section 32 of turbine 16 to provide propulsive thrust. Simultaneously, as the first portion of air 62 is directed through the bypass airflow passage 56 before exiting from the fan 38 nozzle exhaust section 76 of turbofan 10, the pressure of the first portion of air 62 increases significantly, also providing propulsive thrust. HP turbine 28, LP turbine 30, and injection exhaust nozzle section 32 at least partially define a hot gas path 78 for directing combustion gas 66 through turbine 16.

[0034] However, it should be understood that, Figure 1The exemplary turbofan engine 10 depicted is merely an example, and in other exemplary embodiments, the turbofan engine 10 may have any other suitable configuration. For example, in other exemplary embodiments, the fan 38 may be configured as a variable-pitch fan, including, for example, suitable actuation components for rotating a plurality of fan blades about their respective pitch axes, and the turbofan engine 10 may be configured as a geared turbofan engine, having a reduction gearbox, etc., between the LP shaft 36 and the fan section 14. It should also be understood that, in other exemplary embodiments, aspects of this disclosure may be incorporated into any other suitable gas turbine engine. For example, in other exemplary embodiments, multiple aspects of this disclosure may be incorporated into, for example, a turboprop engine.

[0035] Now refer to Figure 2 and Figure 3 . Figure 2 Provided Figure 1 Perspective view of fan assembly 14. Figure 3 Provided Figure 2 A side view of the fan blade 100 of the fan assembly 14. Although the airfoil shown is depicted as fan blade 100, it should be understood that the following discussion is equally applicable to another airfoil embodiment, such as the outlet guide vanes, stator vanes, or rotor blades of compressors 22, 24 and / or turbines 28, 32 (see [reference]). Figure 1 ).

[0036] As shown in the figure, each fan blade 100 extends outward along the local spanwise direction S (see figure). Figure 3 In addition, each fan blade 100 includes a body 102 extending from the root 104 to the tip 106 along the spanwise direction S. The spanwise direction S can generally be aligned with the radial direction R of the engine in which the fan assembly 14 is incorporated. Each fan blade 100 may further define a wingspan 108 along the spanwise direction S. The wingspan 108 is defined by the distance along the spanwise centerline of the fan blade 100 from the root 104 to the tip 106 in the spanwise direction S. The body 102 of each fan blade 100 also defines a pressure side 110, a suction side 112, a leading edge 114, and a trailing edge 116. The pressure side 110 and suction side 112 of the body 102 of the fan blade 100 extend from the leading edge 114 to the trailing edge 116 of the fan blade 100 and extend along the spanwise direction S between the root 104 and the tip 106.

[0037] Furthermore, it should be recognized that the body 102 of the fan blade 100 may define a chordal direction C along a chord 118 at each point along the wingspan 108, extending between the leading edge 114 and the trailing edge 116. The chord 118 is typically the distance from the leading edge 114 to the trailing edge 116, and the chordal direction C is typically the direction at a given wingspan position between the leading edge 114 and the trailing edge 116. Furthermore, the chord 118 may vary along the wingspan 108 of the fan blade 100. For example, in the depicted embodiment, the chord 118 increases along the wingspan 108 towards the tip 106. However, in other embodiments, the chord 118 may be substantially constant over the entire wingspan 108, or may decrease from the root 104 to the tip 106.

[0038] In the illustrated embodiment, each fan blade 100 also includes an axial dovetail tenon 120 initially formed together with the body 102 of the fan blade 100. The axial dovetail tenon 120 includes a pair of opposing pressure surfaces 122 leading to the transition section 124. Figure 2 As shown, when installed in the fan assembly 14, the dovetail tenon 120 is disposed in the dovetail groove of the fan rotor disk 126, thereby attaching the fan blade 100 to the fan assembly 14.

[0039] Figure 3 The body 102 of the fan blade 100 may have a hollow structure. In another example, the fan blade 100 may include one or more cavities for purposes such as cooling. Alternatively, the body 102 of the fan blade 100 may be a solid structure.

[0040] In one embodiment, the body 102 of the fan blade 100 may include at least one composite layer. More specifically, in at least some exemplary embodiments, the body 102 of the airfoil may be formed substantially of a composite material, for example, substantially entirely of a composite material.

[0041] As used herein, the term "composite material" can be defined as a material containing reinforcements, such as fibers or particles supported in a binder or matrix material. Composite materials include both metallic and non-metallic composites. One useful embodiment of a composite airfoil is made of a unidirectional strip material and an epoxy resin matrix. Composite airfoils disclosed herein can include non-metallic composites made of fiber-containing materials, such as carbonaceous, silica, metals, metal oxides, or ceramic fibers embedded in resin materials, such as epoxy resins, PMR15, BMI, PEEU, etc. More specifically, materials include fibers unidirectionally arranged in a strip, which is impregnated with resin to form a part shape and cured by autoclaving or compression molding to form a lightweight, rigid, relatively homogeneous article in which layers are stacked. However, any suitable composite material and / or forming process can be used.

[0042] Alternatively or alternatively, although not depicted, the fan blade 100 may be formed of any other suitable material and may include one or more reinforcing portions, such as those added to the leading edge 114, trailing edge 116, or both, for example, one or more of metal-reinforced materials, shape memory alloy materials, etc.

[0043] More specifically, now refer to Figure 4 A cross-sectional view of an airfoil 200 according to an exemplary embodiment of the present disclosure is provided. In some exemplary aspects, Figure 4 The 200 airfoil can be used with Figure 3 The fan blades are configured in a similar manner to 100, and Figure 4 The view in can be along Figure 3 The cross-sectional view of line 4-4 in the diagram.

[0044] In this way, it will be understood that the airfoil 200 defines the spanwise direction S, the root 204, and the tip 206, and further, the airfoil 200 includes a body 202, which defines a pressure side 210 and a suction side 212 and extends along the spanwise direction S between the root 204 and the tip 206. The body 202 may be formed of a composite material.

[0045] From Figure 4 As understood from the cross-sectional view, airfoil 200 may additionally include one or more components or features for increasing the strength of airfoil 200. More specifically, for the illustrated embodiment, airfoil 200 also includes a sparsity enclosed within the body 202 of airfoil 200, extending along the spanwise direction S. The sparsity includes a plurality of sparsity segments arranged in an overlapping configuration along the spanwise direction S.

[0046] More specifically, for the exemplary embodiment depicted, the spar is a first spar 226 and the airfoil 200 also includes a second spar 228. In the illustrated embodiment, the first spar 226 is a pressure-side spar and the second spar 228 is a suction-side spar. Also briefly referenced... Figure 5 , Figure 5 Provided along Figure 4 The cross-sectional view of airfoil 200 shown in line 5-5 should be understood to show that the first sparsor 226 and the second sparsor 228 extend generally along the chordal direction C of airfoil 200. In the illustrated embodiment, the first sparsor 226 and the second sparsor 228 each extend at least about 50% of the chordal direction C of airfoil 200. However, in other embodiments, the first sparsor 226, the second sparsor 228, or both may extend less than 50% of the chord of airfoil 200 in the chordal direction C.

[0047] Refer again Figure 4 For more specific references Figure 4The first wing spar 226, as should be understood, comprises multiple wing spar segments that overlap each other and are joined together at their respective lap joints. The term "lap joint" generally refers to any joint in which two components are joined together using an adhesive between two adjacent surfaces.

[0048] However, it should be understood that in other exemplary aspects, other suitable joints may be used to attach multiple spar segments, such as joints formed by complementary geometries, joints using mechanical fasteners, etc.

[0049] More specifically, in the illustrated embodiment, the first wing spar 226 includes a first wing spar segment 230, a second wing spar segment 232, and a third wing spar segment 234. The first wing spar segment 230 overlaps with the second wing spar segment 232 and is joined to the second wing spar segment 232 at a first lap joint 236, and similarly, the second wing spar segment 232 overlaps with the third wing spar segment 234 and is joined to the third wing spar segment 234 at a second lap joint 238.

[0050] It should be understood that although the first spar segment 230 includes three spar segments in the illustrated embodiment, the first spar 226 may include any other suitable number of spar segments in other exemplary embodiments. For example, in some exemplary embodiments, the first spar 226 may include two spar segments, at least four spar segments, at least five spar segments, at least six spar segments, up to 30 spar segments, up to 25 spar segments, up to 20 spar segments, up to 15 spar segments, or up to 10 spar segments.

[0051] More specifically, see special reference Figure 6 A close-up view of the first lap joint 236 is provided. It should be understood that the first spar segment 230 is bonded to the second spar segment 232 using adhesive 240. In the illustrated embodiment, adhesive 240 is a single-layer adhesive 240; however, in other embodiments, multiple spar segments may be bonded together using any suitable amount of adhesive, adhesive type, etc.

[0052] Also from Figure 6 A close-up view reveals that multiple spar segments of the first spar 226 are formed of composite materials. More specifically, the multiple spar segments are individually formed of composite materials and subsequently bonded together using adhesive 240. For example, from... Figure 6 It is understood that the first spar segment 230 includes a plurality of fibers 242, and the second spar segment 232 similarly includes a plurality of fibers 244. The fibers 242 of the first spar segment 230 do not overlap and / or mix with the fibers 244 of the second spar segment 232.

[0053] In this way, it should be understood that when external stress or force is applied to the airfoil 200, the airfoil 200 can be designed to fail at the joint between adjacent spar segments of a particular spar. In this way, the airfoil 200 according to this disclosure can be configured as a fragile airfoil with a predetermined failure point at the joint between adjacent spar segments of a particular spar.

[0054] It will be further understood that aspects of one or more spars included in the airfoil 200 can be designed to specify how much stress is required to break a particular point of the airfoil 200, and further, aspects of the airfoil can be designed to indicate the location where the airfoil 200 is configured to break first.

[0055] For example, now return to the reference. Figure 4 It should be understood that the first wing sparsity segment 230 overlaps with the second wing sparsity segment 232 at a first overlapping section 246 of the first wing sparsity segment 230. The first wing sparsity segment 230 defines a first total length 248 along the longitudinal direction of the first wing sparsity segment 230, and a first overlap length 250 of the first overlapping section 246 of the first wing sparsity segment 230, also along the longitudinal direction of the first wing sparsity segment 230. In the illustrated embodiment, the first wing sparsity segment 230 is arranged generally along the wingspan direction S. In this way, it should be understood that the first total length 248 is defined along the wingspan direction S, and the first overlap length 250 is similarly defined along the wingspan direction S. In the illustrated embodiment, the first overlap length 250 is equal to or less than 15% of the first total length 248. In some embodiments, the first total length 248 may be equal to or less than 12% of the first total length 248, for example equal to or less than 10%, for example equal to or less than 8%, for example equal to or less than 5% of the first total length 248, and equal to at least about 2% of the first total length 248, for example at least about 4%, for example at least about 6%.

[0056] Furthermore, in the illustrated embodiment, as described above, the first spar 226 further includes a third spar segment 234. The second spar segment 232 overlaps with the third spar segment 234 at a second overlapping section 252 of the second spar segment 232. The second spar segment 232 defines a second total length 254 along the longitudinal direction of the second spar segment 232 and a second overlap length 256 along the longitudinal direction of the second overlapping section 252. Similar to the first spar segment 230, in the illustrated embodiment, the second spar segment 232 is arranged generally along the wingspan direction S. In this way, it will be understood that the second total length 254 is defined along the wingspan direction S, and the second overlap length 256 is similarly defined along the wingspan direction S. In the illustrated embodiment, the second overlap length 256 may be equal to the first overlap length 250. In this way, it should be understood that the second overlap length 256 may be equal to or less than 15% of the first total length 248. In some embodiments, the second overlap length 256 may be equal to or less than 12% of the first total length 248, for example equal to or less than 10%, for example equal to or less than 8%, for example equal to or less than 5%, and equal to at least about 2% of the first total length 248, for example at least about 4%, for example at least about 6%.

[0057] Furthermore, it should be understood that, for the illustrated embodiment, the spar segment of the first spar 226 may not be limited to a uniform length. More specifically, for the illustrated embodiment, the first total length 248 of the first spar segment 230 is greater than the second total length 254 of the second spar segment 232. For example, the second total length 254 may be less than 95% of the first total length 248, for example less than 90% of the first total length 248, for example less than 85% of the first total length 248, for example less than 80% of the first total length 248. Furthermore, the second total length 254 may be equal to at least about 25% of the first total length 248, for example at least about 50% of the first total length 248, for example equal to at least 75% of the first total length 248.

[0058] Similarly, in the illustrated embodiment, the third spar segment 234 may be defined as a third total length 258 that is not equal to the first total length 248 or the second total length 254. More specifically, in the illustrated embodiment, the third total length 258 of the third spar segment 234 is less than the second total length 254 of the second spar segment 232. For example, the total length may be less than 95% of the second total length 254, for example, less than 90% of the second total length 254, for example, less than 85% of the second total length 254, for example, less than 80% of the second total length 254. Furthermore, the third total length 258 may be equal to at least about 25% of the second total length 254, for example, at least about 50% of the second total length 254, for example, at least 75% of the second total length 254.

[0059] Still referencing Figure 4It should be understood that, for the illustrated embodiment, the second spar 228 similarly includes multiple spar segments, more specifically, a first spar segment 260, a second spar segment 262, and a third spar segment 264. For the illustrated embodiment, the first spar 226 is substantially a mirror image of the second spar 228. More specifically, for the illustrated embodiment, the first spar 226 includes the same number of spar segments as the second spar 228, each spar segment of the first spar 226 corresponding in size and span position to a spar segment of the second spar 228 (e.g., first spar segments 230, 260 having the same total length and span position, second spar segments 232, 262 having the same total length and span position, and third spar segments 234, 264 having the same total length and span position). In this way, it should be understood that the first spar 226 defines multiple overlapping segments (segments 246, 252) and the second spar 228 similarly defines multiple overlapping segments. Figure 4 In one embodiment, multiple overlapping sections (sections 246, 252) of the first wing beam 226 are arranged in a similar configuration to the multiple overlapping sections of the second wing beam 228.

[0060] It should be understood that, despite Figure 4 In the illustrated embodiment, the length of the spar segment varies in the spanwise direction S, decreasing from the root end 204 to the tip end 206. However, in other exemplary embodiments, the length of the spar segment varies in the spanwise direction S, increasing from the root end 204 to the tip end 206.

[0061] It should also be understood that in other exemplary embodiments, the airfoil 200 may be provided with any other suitable configuration. For example, now referring to Figure 7 A cross-sectional view of an airfoil 200 according to another exemplary embodiment of the present disclosure is provided.

[0062] Figure 7 The exemplary airfoil 200 can be used with Figure 4 The exemplary airfoil 200 is configured in a similar manner. For example, Figure 7 An exemplary airfoil 200 typically includes a body 202 that defines a pressure side 210 and a suction side 212 and extends along the wingspan direction S between a root end 204 and a tip 206. Figure 7 The body 202 of the airfoil 200 can be similarly formed from composite materials.

[0063] also, Figure 7 The exemplary airfoil 200 depicted also includes a spars surrounding a body 202 of the airfoil 200, the spars having multiple spars segments arranged in an overlapping configuration. More specifically, Figure 7The airfoil 200 depicted includes a first sparb 226 and a second sparb 228. The first sparb 226 includes a first sparb segment 230, a second sparb segment 232, and a third sparb segment 234. However, compared with... Figure 4 The first wing spars 226 is opposite to, for Figure 7 In one embodiment, the first wing segment 230 defines a first total length 248, which is substantially equal to the second total length 254 of the second wing segment 232 and substantially equal to the third total length 258 of the third wing segment 234.

[0064] In this way, it should be understood that, for Figure 7 In one embodiment, at least two of the plurality of spar segments of the first spar 226 are defined with substantially the same total length, or more specifically, for Figure 7 In an exemplary embodiment, each of the plurality of spar segments of the first spar 226 defines substantially the same total length.

[0065] Further comparison, for Figure 7 In the embodiments described, it should be understood that the first spar segment 230 defines a first overlap length 250 of the first overlapping segment 246 (where the first spar segment 230 overlaps with the second spar segment 232), and the second spar segment 232 defines a second overlap length 256 of the second overlapping segment 252 (where the second spar segment 232 overlaps with the third spar segment 234). In the illustrated embodiment, the first overlap length 250 is not equal to the second overlap length 256.

[0066] More specifically, in the illustrated embodiment, the first overlap length 250 is greater than the second overlap length 256. It should also be understood that, in the illustrated embodiment, the first spar segment 230 is closer to the root end 204 of the body 202 of the airfoil 200 than the second spar segment 232, and further, the second spar segment 232 is closer to the root end 204 of the body 202 of the airfoil 200 than the third spar segment 234. As will be understood, the first overlap length 250 is greater than the second overlap length 256, more specifically, the first overlap length 250 is equal to at least 110% of the second overlap length 256, for example, at least 125% of the second overlap length 256, for example, at least 150% of the second overlap length 256, for example, at least 200% of the second overlap length 256, for example, up to 5000% of the second overlap length 256.

[0067] In this way, it should be understood that the first spar 226 can be defined as having a failure point at the second overlapping section 252 and a failure point at the first overlapping section 246, wherein the failure point at the second overlapping section 252 is designed to age under stress less than the stress that would cause the first spar 226 to fail at the first overlapping section 246. In this way, the airfoil 200 can be configured to fail at an outer position along the spanwise direction S before failing at an inner position along the spanwise direction S.

[0068] It will also understand that, for Figure 7 In the illustrated embodiment, the second spar 228 is configured in a similar manner to the first spar 226; however, in the illustrated embodiment, the first spar 226 is not a mirror image of the second spar 228. For example, in the illustrated embodiment, it should be understood that the first spar 226 defines a plurality of overlapping segments (overlapping segments 246, 252) and the second spar 228 similarly defines a plurality of overlapping segments, but the plurality of overlapping segments (overlapping segments 246, 252) of the first spar 226 are arranged in a unique configuration relative to the plurality of overlapping segments of the second spar 228. More specifically, in the illustrated embodiment, the plurality of overlapping segments of the second spar 228 are arranged at different span positions than the plurality of overlapping segments of the first spar 226. However, in other exemplary embodiments, the plurality of overlapping segments of the second spar 228 may alternatively define unique overlap lengths, may include a different number of overlapping segments relative to the plurality of overlapping segments of the first spar 226, and so on.

[0069] Furthermore, in other exemplary embodiments of this disclosure, the first spar 226, the second spar 228, or both may have other suitable configurations. For example, see brief reference. Figure 8 A cross-sectional view of an airfoil 200 according to another exemplary embodiment of the present disclosure is provided, wherein the plurality of spar segments of the first spar 226 may not be precisely arranged along the span direction of the airfoil 200, but may be defined at an angle relative to the span direction S of the airfoil 200. Similarly, for Figure 8 In this embodiment, the multiple spar segments of the second spar 228 do not extend precisely along the span direction S of the airfoil 200, but are defined at an angle relative to the span direction S of the airfoil 200. In the illustrated embodiment, moving from the root end 204 of the body 202 of the airfoil 200 to the tip end 206 of the body 202 of the airfoil 200, the multiple spar segments of the first spar 226 gradually taper toward the multiple spar segments of the second spar 228, and similarly, moving from the root end 204 of the body 202 of the airfoil 200 to the tip end 206 of the body 202 of the airfoil 200, the multiple spar segments of the second spar 228 gradually taper toward the multiple spar segments of the first spar 226.

[0070] It should be understood that, although the above references Figures 1 to 8The exemplary airfoil 200 described is generally described as having two spars (a first spar 226 and a second spar 228); however, in other exemplary aspects of this disclosure, the airfoil 200 may include only a single spar 200, for example, positioned along the centerline of the airfoil 200. Further in other exemplary embodiments, the airfoil 200 may include more than two spars, for example, up to ten spars.

[0071] This will be further understood, despite the above references Figures 1 to 8 The exemplary airfoil 200 described herein is generally referred to with respect to the fan blade 100 of a gas turbine engine fan. In other exemplary embodiments, the above-described configuration may be applied to any other suitable airfoil 200, such as any other suitable airfoil 200 for a gas turbine engine. For example, in other exemplary embodiments, aspects of this disclosure may be incorporated into, for example, one or more outlet guide vanes (e.g., Figure 1 Examples include the outlet guide vane 52), one or more compressor rotor blades, compressor stator blades, turbine rotor blades, turbine stator blades, nozzles, supports, etc.

[0072] This written description uses examples to disclose the invention, including the best mode, and also enables any person skilled in the art to practice the invention, including making and using any device or system and performing any combined methods. The patent scope of the invention is defined by the claims, but may include other examples that would occur to a person skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that are not indistinguishable from the literal language of the claims, or if they include equivalent structural elements that are not substantially different from the literal language of the claims.

[0073] Further aspects are provided by the subject matter of the following clauses:

[0074] An airfoil defining a spanwise direction, a root end, and a tip end, the airfoil comprising: a body defining a pressure side and a suction side and extending in the spanwise direction between the root end and the tip end, the body being made of a composite material; and a sparsity surrounding the body of the airfoil and extending in the spanwise direction, the sparsity comprising a plurality of sparsity segments arranged in an overlapping configuration in the spanwise direction.

[0075] According to one or more of these clauses, each of the plurality of spar segments is formed of a composite material.

[0076] According to one or more of these clauses, the airfoil includes a first spar segment and a second spar segment, wherein the first spar segment and the second spar segment are respectively formed of composite materials and joined together.

[0077] According to one or more of these terms, the airfoil includes a first spar segment and a second spar segment, wherein the first spar segment is bonded to the second spar segment using an adhesive.

[0078] According to one or more of these terms, the airfoil includes a first wing spar segment and a second wing spar segment, wherein the first wing spar segment and the second wing spar segment are joined together at an overlap joint.

[0079] According to one or more of these clauses, the airfoil is a first spar, and the body of the airfoil also includes a second spar, wherein the first spar is a pressure-side spar and the second spar is a suction-side spar.

[0080] According to one or more of these clauses, the airfoil is substantially mirror-image of the first spar and the second spar.

[0081] According to one or more of these clauses, the airfoil defines a plurality of overlapping sections, the second spar defines a plurality of overlapping sections, and the plurality of overlapping sections of the first spar are arranged in a unique configuration relative to the plurality of overlapping sections of the second spar.

[0082] According to one or more of these terms, the airfoil comprises at least three spar segments and up to thirty spars.

[0083] According to one or more of these clauses, the airfoil includes a plurality of spar segments comprising a first spar segment and a second spar segment, wherein the first spar segment overlaps with the second spar segment at a first overlapping section of the first spar segment, wherein the first spar segment defines a first total length and a first overlap length of the first overlapping section, wherein the first overlap length is equal to or less than 15% of the first total length.

[0084] According to one or more of these clauses, the airfoil further includes a third spar segment, wherein the second spar segment overlaps with the third spar segment at a second overlapping section of the second spar segment, wherein the second spar segment defines a second overlap length of the second overlapping section, wherein the second overlap length is equal to or less than 15% of the first total length.

[0085] According to one or more of these clauses, the airfoil length is not equal to the second overlap length.

[0086] According to one or more of these clauses, the airfoil segment is closer to the root end than the second spar segment, the second spar segment is closer to the root end than the third spar segment, and the first overlap length is greater than the second overlap length.

[0087] According to one or more of these clauses, the airfoil segment is closer to the root end than the second airfoil segment, the second airfoil segment is closer to the root end than the third airfoil segment, the second airfoil segment also defines a second total length, and the first total length is greater than the second total length.

[0088] A gas turbine engine includes: an airfoil defining a spanwise direction, a root end, and a tip end, the airfoil including a body defining a pressure side and a suction side and extending in the spanwise direction between the root end and the tip end, the body being made of a composite material; and a sparsity surrounding the body of the airfoil and extending in the spanwise direction, the sparsity including a plurality of sparsity segments arranged in an overlapping configuration in the spanwise direction.

[0089] The gas turbine engine according to one or more of these provisions also includes a fan and a turbine, wherein the fan is driven by the turbine, and wherein the airfoil is the fan blade of the fan.

[0090] According to one or more of these provisions, a gas turbine engine includes a plurality of spar segments comprising a first spar segment and a second spar segment, wherein the first spar segment overlaps with the second spar segment at a first overlapping section of the first spar segment, wherein the first spar segment defines a first total length and a first overlap length of the first overlapping section, wherein the first overlap length is equal to or less than 15% of the first total length.

[0091] According to one or more of these provisions, the gas turbine engine further includes a third spar segment, wherein a second spar segment overlaps with the third spar segment at a second overlap section of the second spar segment, wherein the second spar segment defines a second overlap length of the second overlap section, wherein the second overlap length is equal to or less than 15% of the first total length.

[0092] According to one or more of these clauses, a gas turbine engine is provided in which a first spar segment is closer to the root end than a second spar segment, a second spar segment is closer to the root end than a third spar segment, and a first overlap length is greater than a second overlap length.

[0093] According to one or more of these clauses, a gas turbine engine is provided in which a first spar segment is closer to the root end than a second spar segment, a second spar segment is closer to the root end than a third spar segment, a second spar segment further defines a second overall length, and a first overall length is greater than a second overall length.

Claims

1. An airfoil defining a spanwise direction, a root end, and a tip end, characterized in that, The airfoil includes: Body, the body defining a pressure side and a suction side and extending along the wingspan direction between the root end and the tip end, the body being formed of a composite material; and A spar, which surrounds the body of the airfoil and extends along the span direction, the spar comprising a plurality of spar segments arranged in an overlapping configuration along the span direction; The spar is a first spar, the body of the airfoil further includes a second spar, the first spar is a pressure-side spar and the second spar is a suction-side spar, the first spar defines a plurality of overlapping sections, the second spar defines a plurality of overlapping sections, and the plurality of overlapping sections of the second spar are arranged at different span positions than the plurality of overlapping sections of the first spar.

2. The airfoil according to claim 1, characterized in that, in, Each of the plurality of wing spar segments is formed of a composite material.

3. The airfoil according to claim 1, characterized in that, in, The plurality of wing spar segments include a first wing spar segment and a second wing spar segment, wherein the first wing spar segment and the second wing spar segment are respectively formed of composite material and bonded together.

4. The airfoil according to claim 1, characterized in that, in, The plurality of wing spar segments include a first wing spar segment and a second wing spar segment, wherein the first wing spar segment is joined to the second wing spar segment.

5. The airfoil according to claim 1, characterized in that, in, The plurality of wing beam segments include a first wing beam segment and a second wing beam segment, wherein the first wing beam segment and the second wing beam segment are bonded together at an overlap joint.

6. The airfoil according to claim 1, characterized in that, in, The first spar and the second spar are essentially mirror images of each other.

7. The airfoil according to claim 1, characterized in that, in, The plurality of wing spars includes at least three wing spars and up to thirty wing spars.

8. The airfoil according to claim 1, characterized in that, in, The plurality of spar segments include a first spar segment and a second spar segment, wherein the first spar segment overlaps with the second spar segment at a first overlapping section of the first spar segment, wherein the first spar segment defines a first total length and a first overlap length of the first overlapping section, wherein the first overlap length is equal to or less than 15% of the first total length.

9. The airfoil according to claim 8, characterized in that, in, The plurality of spar segments further includes a third spar segment, wherein the second spar segment overlaps with the third spar segment at a second overlapping section of the second spar segment, wherein the second spar segment defines a second overlap length of the second overlapping section, wherein the second overlap length is equal to or less than 15% of the first total length.

10. The airfoil according to claim 9, characterized in that, in, The first overlap length is not equal to the second overlap length.

11. The airfoil according to claim 9, characterized in that, in, The first spar segment is closer to the root end than the second spar segment, wherein the second spar segment is closer to the root end than the third spar segment, and wherein the first overlap length is greater than the second overlap length.

12. The airfoil according to claim 9, characterized in that, in, The first spar segment is closer to the root end than the second spar segment, wherein the second spar segment is closer to the root end than the third spar segment, wherein the second spar segment also defines a second total length, and wherein the first total length is greater than the second total length.

13. A gas turbine engine, characterized in that, include: Airfoil, defining the spanwise direction, root end, and tip end, the airfoil comprising: Body, the body defining a pressure side and a suction side and extending along the wingspan direction between the root end and the tip end, the body being formed of a composite material; and A spar, which surrounds the body of the airfoil and extends along the span direction, the spar comprising a plurality of spar segments arranged in an overlapping configuration along the span direction; The spar is a first spar, the body of the airfoil further includes a second spar, the first spar is a pressure-side spar and the second spar is a suction-side spar, the first spar defines a plurality of overlapping sections, the second spar defines a plurality of overlapping sections, and the plurality of overlapping sections of the second spar are arranged at different span positions than the plurality of overlapping sections of the first spar.

14. The gas turbine engine according to claim 13, characterized in that, It also includes a fan and a turbine, wherein the fan is driven by the turbine, and wherein the airfoil is the fan blade of the fan.

15. The gas turbine engine according to claim 13, characterized in that, in, The plurality of spar segments include a first spar segment and a second spar segment, wherein the first spar segment overlaps with the second spar segment at a first overlapping section of the first spar segment, wherein the first spar segment defines a first total length and a first overlap length of the first overlapping section, wherein the first overlap length is equal to or less than 15% of the first total length.

16. The gas turbine engine according to claim 15, characterized in that, in, The plurality of spar segments further includes a third spar segment, wherein the second spar segment overlaps with the third spar segment at a second overlapping section of the second spar segment, wherein the second spar segment defines a second overlap length of the second overlapping section, wherein the second overlap length is equal to or less than 15% of the first total length.

17. The gas turbine engine according to claim 16, characterized in that, in, The first spar segment is closer to the root end than the second spar segment, wherein the second spar segment is closer to the root end than the third spar segment, and wherein the first overlap length is greater than the second overlap length.

18. The gas turbine engine according to claim 16, characterized in that, in, The first spar segment is closer to the root end than the second spar segment, wherein the second spar segment is closer to the root end than the third spar segment, wherein the second spar segment also defines a second total length, and wherein the first total length is greater than the second total length.

19. A gas turbine engine, characterized in that, include: Airfoil, defining the spanwise direction, root end, and tip end, the airfoil comprising: Body, the body defining a pressure side and a suction side and extending along the wingspan direction between the root end and the tip end, the body being formed of a composite material; and A spar, which surrounds the body of the airfoil and extends along the span direction, the spar comprising a plurality of spar segments arranged in an overlapping configuration along the span direction; The plurality of wing spar segments include a first wing spar segment and a second wing spar segment, wherein the first wing spar segment overlaps with the second wing spar segment at a first overlapping section of the first wing spar segment, wherein the first wing spar segment defines a first total length and a first overlap length of the first overlapping section, wherein the first overlap length is equal to or less than 15% of the first total length.

20. The gas turbine engine according to claim 19, characterized in that, It also includes a fan and a turbine, wherein the fan is driven by the turbine, and wherein the airfoil is the fan blade of the fan.

21. The gas turbine engine according to claim 19, characterized in that, in, The plurality of spar segments further includes a third spar segment, wherein the second spar segment overlaps with the third spar segment at a second overlapping section of the second spar segment, wherein the second spar segment defines a second overlap length of the second overlapping section, wherein the second overlap length is equal to or less than 15% of the first total length.

22. The gas turbine engine according to claim 21, wherein, The first spar segment is closer to the root end than the second spar segment, wherein the second spar segment is closer to the root end than the third spar segment, wherein the second spar segment also defines a second total length, and wherein the first total length is greater than the second total length.

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