Integrated stator-fan frame assembly

Abstract

Methods, apparatus, systems, and articles of manufacture are disclosed to enable an integrated stator-fan frame assembly. An integrated fan exit stator-fan frame strut assembly for a gas turbine engine includes a fan exit stator portion having an airfoil including a leading edge and a trailing edge, and a fan frame strut portion including a leading edge and a trailing edge, the leading edge of the fan frame strut portion aerodynamically integrated with the trailing edge of the fan exit stator portion.

Description

TECHNICAL FIELD

[0001] The present disclosure relates generally to gas turbines, and more particularly, to an integrated stator-fan frame assembly. BACKGROUND

[0002] Gas turbine engines generally include, in serial flow order, an inlet section, a compressor section, a combustion section, a turbine section, and an exhaust section. In operation, air enters the inlet section and flows to the compressor section where one or more axial compressors progressively compress the air until it reaches the combustion section, producing combustion gases. The combustion gases flow from the combustion section through a hot gas path defined within the turbine section, and then exit the turbine section via the exhaust section. BRIEF DESCRIPTION OF DRAWINGS

[0003] Figure 1 An example gas turbine engine is shown.

[0004] Figure 2 An example cross-sectional side view of a first example inlet section of an example gas turbine engine of the prior art is shown.

[0005] Figure 3 An example cross-sectional side view of a second example inlet section of an example gas turbine engine including an integrated fan exit stator (FES)-fan frame strut is shown.

[0006] Figure 4 An expanded view of a portion of the second example inlet section including the integrated FES-fan frame strut is shown. Figure 3

[0007] Figure 5A A first example configuration of a joint of a first example integrated FES-fan frame strut is shown.

[0008] Figure 5B A second example configuration of a joint of a second example integrated FES-fan frame strut is shown.

[0009] Figure 5C A third example configuration of a joint of a third example integrated FES-fan frame strut is shown.

[0010] ​Generally, the same reference numerals will be used throughout the accompanying drawings and written description to refer to the same or similar parts. These drawings are not drawn to scale. Instead, the thickness of layers or regions may be enlarged in the drawings. While layers and regions with sharp lines and boundaries are shown in the figures, the lines and / or boundaries of these parts or all may be idealized. In reality, boundaries and / or lines may be imperceptible, mixed, and / or irregular. As used herein, unless otherwise stated, the term "above" refers to the relationship between two parts relative to the ground. If at least part of the second part is between the ground and the first part, then the first part is above the second part. Similarly, as used herein, the first part is "below" the second part when the first part is closer to the ground than the second part. As stated above, the first part may be above or below the second part, with one or more of the following in between: there are other parts between them, there are no other parts between them, the first and second parts are in contact, or the first and second parts are not in direct contact with each other.

[0011] As used in this patent, it is said that any part (e.g., layer, film, region, area, or plate) is located on (e.g., positioned on, located, arranged on, or formed on, etc.) another part in any way, indicating that the referenced part is either in contact with the other part or is above the other part, and one or more intermediate parts are located between them.

[0012] As used herein, a connection reference (e.g., attachment, coupling, joining, and joining) may include intermediate components between elements referenced by the connection reference and / or relative movement between those elements, unless otherwise stated. Therefore, a connection reference does not necessarily imply that two elements are directly connected and / or have a fixed relationship with each other. As used herein, stating that any part is “in contact” with another part means that there is no intermediate part between the two parts.

[0013] Unless otherwise expressly stated, this document uses descriptors such as “first,” “second,” and “third” without assigning or otherwise indicating any meaning of priority, physical order, arrangement in a list, and / or any order, but only as labels and / or arbitrary names to distinguish elements for the purpose of understanding the disclosed examples. In some examples, the descriptor “first” may be used to refer to an element in the detailed description, while different descriptors (e.g., “second” or “third”) may be used in the claims to refer to the same element. In such cases, it should be understood that the use of such descriptors is merely for the purpose of distinguishing elements that, for example, otherwise share the same name.

[0014] As used herein, “approximately” and “about” mean dimensions that can not be exact, as a result of manufacturing tolerances, and / or other real-world imperfections. As used herein, “substantially the same dimensions” means dimensions that can not be exactly the same, as a result of manufacturing tolerances, and / or other real-world imperfections. Thus, unless otherwise specified, “substantially the same dimensions” means + / - 10% of the dimensions. As used herein, the phrase “in communication,” including variants thereof, encompasses direct communication and / or indirect communication through one or more intermediary components and does not require direct physical (e.g., wired) communication and / or constant communication, but additionally includes selective communication at periodic intervals, predetermined intervals, aperiodic intervals, and / or one-time events. DETAILED DESCRIPTION

[0015] Many known technologies aim to reduce the mass of a gas turbine engine while at least maintaining technical specifications and / or performance. For example, some technologies can reduce the mass of one or more components by using advanced materials (e.g., composites). In other examples, technologies can be used to reduce the size of one or more components to reduce mass. The examples disclosed herein can provide a reduced length and thus reduced mass of a low pressure shaft and / or a fan shaft of a gas turbine engine while maintaining technical performance of the gas turbine engine by implementing an integrated fan exit stator-fan frame strut assembly. Other known technologies aim to improve the performance of a gas turbine engine. For example, some technologies can aim to improve the performance (e.g., thrust, fuel economy, etc.) of a gas turbine engine while maintaining a given packaging size (e.g., diameter of the fan case).

[0016] In the following detailed description, reference is made to the accompanying drawings, which form a part hereof, and in which are shown, by way of illustration, specific examples in which the subject matter can be practiced. These examples are described in sufficient detail to enable those skilled in the art to practice the subject matter, and it is to be understood that other examples can be utilized. Thus, the following detailed description is presented in order to describe examples implementing the subject matter and not to limit the scope of the subject matter described in this disclosure. Certain features from the different aspects of the following description can be combined to form yet another aspect of the subject matter discussed below.

[0017] The terms “upstream” and “downstream” refer to the relative direction with respect to the flow of fluid in a fluid pathway. For example, “upstream” refers to the direction from which the fluid comes, and “downstream” refers to the direction to which the fluid flows. As used herein, “vertical” refers to a direction perpendicular to the ground. As used herein, “horizontal” refers to a direction parallel to the centerline of the turbofan 100. As used herein, “lateral” refers to a direction perpendicular to the axial vertical direction (e.g., the plane into and out of the page of FIG. 1, etc.). Figure 1 、 2

[0018] ​Various terms are used herein to describe the orientation of features. As used herein, the orientation of features, forces, and moments are described with reference to axial, radial, and circumferential directions of a vehicle with which the features, forces, and moments are associated. Generally, the drawings utilize a set of axes including an axial axis A, a radial axis R, and a circumferential axis C for notation. Additionally or alternatively, the drawings utilize a set of axes including a roll axis R, a pitch axis P, and a yaw axis Y for notation.

[0019] “Include” and “comprise” (and all forms of these terms) are used herein as open-ended terms. Thus, whenever a claim employs any form of “include” or “comprise” (e.g., includes, comprising, included, comprising, having, and the like) as a preamble, it should be understood that additional elements, terms, etc. can be present in the corresponding claim or statement without exceeding the scope of the corresponding claim or statement. As used herein, the phrase “at least” is used as an open-ended term to mean that the recited term can be present at least once, but that additional terms can also be present. As used herein, the term “and / or” means any one or all of the associated listed items, e.g., A, B, and / or C, can be included in the phrase “A, B, and / or C.” As used herein in the context of describing structural, component, item, object, and / or thing, the phrase “at least one of A and B” means embodiments including any one of the following: (1) at least one A, (2) at least one B, and (3) at least one A and at least one B. Similarly, as used herein in the context of describing structural, component, item, object, and / or thing, the phrase “at least one of A or B” means embodiments including any one of the following: (1) at least one A, (2) at least one B, and (3) at least one A and at least one B. As used herein in the context of describing performance or execution of a process, instruction, action, activity, and / or step, the phrase “at least one of A or B” means embodiments including any one of the following: (1) at least one A, (2) at least one B, and (3) at least one A and at least one B. Similarly, as used herein in the context of describing performance or execution of a process, instruction, action, activity, and / or step, the phrase “at least one of A or B” means embodiments including any one of the following: (1) at least one A, (2) at least one B, and (3) at least one A and at least one B.

[0020] As used herein, singular references (e.g., “a”, “an”, “first”, “second”, and the like) are not excluded from a plural interpretation unless the context clearly dictates otherwise. As used herein, the term “a” or “an” entity refers to one or more than one of that entity. The terms “a” (or “an”), “one or more”, and “at least one” are used interchangeably herein. Furthermore, although individually listed, a plurality of means, elements or method actions can be implemented by, e.g., a single unit or processor. Additionally, although individual features can be included in different examples or claims, these can be combined, and the inclusion in different examples or claims does not imply that a combination of features is not feasible and / or advantageous.

[0021] Gas turbine engines include a fan section proximate to an engine air intake. The fan section includes a plurality of circumferentially spaced apart fan blades. A rotating portion of the fan section including the fan blades is rotatably coupled to a low pressure (LP) compressor (e.g., booster) via an LP shaft. In some examples, the LP shaft includes an LP shaft portion and a fan shaft portion. To facilitate the directing of airflow from the fan section into the LP compressor, some known gas turbine engines include a plurality of circumferentially spaced apart fan outlet stators. In some known gas turbine engines, a reduction gearbox is employed to couple the LP shaft and the fan shaft while reducing the speed of the fan shaft relative to the LP shaft. Reducing the speed of the fan shaft in this manner allows for a reduction in fan blade tip speed. However, due to the packaging of the reduction gearbox, such gas turbine engines have an axial space between the fan outlet stators and the LP compressor. Accordingly, a fan frame strut is employed to support the airflow path between the fan outlet stators and the LP compressor. In some examples, the fan frame strut is disposed axially downstream within the airflow path adjacent to the fan outlet stators. Examples disclosed herein aerodynamically integrate the fan frame strut with the fan outlet stators as a stator-strut assembly. Examples disclosed herein reduce the length of the fan shaft by integrating the fan frame strut with the fan outlet stators. Examples disclosed herein reduce the length of the gas turbine engine by reducing the length of the fan shaft. Examples disclosed herein increase the duct region downstream of the fan section, thereby reducing the air flow velocity through the duct and the duct surface friction losses.

[0022] Reference will now be made in detail to examples of the present disclosure, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the present disclosure and is not meant as a limitation of the present disclosure. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present disclosure without departing from the scope or spirit of the disclosure. For instance, features illustrated or described as part of one example, can be used with another example to yield a still further example. Thus, it is intended that the present disclosure cover such modifications and variations of this disclosure provided they come within the scope of the appended claims and their equivalents.

[0023] Figure 1is a schematic cross-sectional view of a prior art turbofan gas turbine engine 100 ("turbofan 100"). As shown, the turbofan 100 defines a longitudinal or axial centerline axis 102 extending therethrough for reference. Generally, the turbofan 100 can include a core turbine 104 or gas turbine engine arranged downstream of a fan section 106. Figure 1

[0024] The core turbine 104 generally includes a substantially tubular outer casing 108 ("turbine casing 108") defining an annular inlet 110. The outer casing 108 can be formed of a single casing or multiple casings. The outer casing 108 encloses, in serial flow relationship, a compressor section having a booster or low pressure compressor 112 ("LP compressor 112") and a high pressure compressor 114 ("HP compressor 114"), a combustion section 116, a turbine section having a high pressure turbine 118 ("HP turbine 118") and a low pressure turbine 120 ("LP turbine 120"), and an exhaust section 122. A high pressure shaft or spool 124 ("HP shaft 124") drivingly couples the HP turbine 118 and the HP compressor 114. A low pressure shaft or spool 126 ("LP shaft 126") drivingly couples the LP turbine 120 and the LP compressor 112. The LP shaft 126 can also be coupled to a fan shaft or spool or axle 128 ("fan shaft 128") of the fan section 106. In some examples, the LP shaft 126 can be directly coupled to the fan shaft 128 (i.e., a direct drive configuration). In alternative configurations, the LP shaft 126 can be coupled to the fan shaft 128 via a reduction gearbox 130 (e.g., an indirect drive or geared drive configuration).

[0025] As shown, the fan section 106 includes a plurality of fan blades 132 coupled to and extending radially outward from the fan shaft 128. An annular fan casing or nacelle 134 circumferentially surrounds at least a portion of the fan section 106 and / or the core turbine 104. The nacelle 134 is supported relative to the core turbine 104 by a plurality of circumferentially spaced outlet guide vanes 136. Further, a downstream section 138 of the nacelle 134 can surround an outer portion of the core turbine 104 to define a bypass airflow passage 140 therebetween. Figure 1

[0026] As shown, the fan section 106 includes a plurality of fan blades 132 coupled to and extending radially outward from the fan shaft 128. An annular fan casing or nacelle 134 circumferentially surrounds at least a portion of the fan section 106 and / or the core turbine 104. The nacelle 134 is supported relative to the core turbine 104 by a plurality of circumferentially spaced outlet guide vanes 136. Further, a downstream section 138 of the nacelle 134 can surround an outer portion of the core turbine 104 to define a bypass airflow passage 140 therebetween. Figure 1 ​​As shown, air 142 enters an inlet portion 144 of the turbofan 100 during operation of the turbofan 100. A first portion 146 of the air 142 flows into the bypass airflow passage 140, while a second portion 148 of the air 142 flows into the annular inlet 110 of the LP compressor 112. One or more sequential stages of LP compressor stator vanes 150 and LP compressor rotor blades 152 coupled to the LP shaft 126 progressively compress the second portion 148 of the air 142 flowing through the LP compressor 112 toward the HP compressor 114. In turn, one or more sequential stages of HP compressor stator vanes 154 and HP compressor rotor blades 156 coupled to the HP shaft 124 further compress the second portion 148 of the air 142 flowing through the HP compressor 114. This provides compressed air 158 to the combustion section 116, where the compressed air is mixed with fuel and combusted to provide combustion gases 160.

[0027] The combustion gases 160 flow through the HP turbine 118, where one or more sequential stages of HP turbine stator vanes 162 and HP turbine rotor blades 164 coupled to the HP shaft 124 extract a first portion of power and / or heat energy from the combustion gases 160. The energy extraction supports operation of the HP compressor 114. The combustion gases 160 then flow through the LP turbine 120, where one or more sequential stages of LP turbine stator vanes 166 and LP turbine rotor blades 168 coupled to the LP shaft 126 extract a second portion of heat and / or kinetic energy therefrom. The energy extraction rotates the LP shaft 126, thereby supporting operation of the LP compressor 112 and / or rotation of the fan shaft 128. The combustion gases 160 then exit the core turbine 104 through its exhaust section 122.

[0028] Along with the turbofan 100, the core turbine 104 has similar purposes and sees similar environments as land-based gas turbines, turbojet engines (where the ratio of the first portion 146 of the air 142 to the second portion 148 of the air 142 is less than that of a turbofan (e.g., the turbofan 100)), and unducted fan engines (where the fan section 106 is absent the nacelle 134). In each of the turbofan, turbojet, and unducted engines, a reduction device (e.g., the reduction gear box 130) can be included between any of the shafts and spools. For example, the reduction gear box 130 can be disposed between the LP shaft 126 and the fan shaft 128 of the fan section 106.

[0029] Figure 2 It is shown that the turbofan 100 can be used in a variety of applications, including as a propulsion system for an aircraft 170, as a power plant for a stationary power generation system 172, and as a power plant for a marine vessel 174. Figure 1The example inlet portion 144 is implemented in the example turbine fan 100 shown. The example inlet portion 144 includes a fan section 106 that rotates about a centerline axis 102 via a fan shaft 128 powered by an LP turbine 120 (not shown). The fan section 106 includes a rotor disk 202 and a plurality of circumferentially spaced fan or rotor blades 132. Figure 2 (Only one is shown in the image) Extending radially outward from rotor disk 202. Fan blades 132 can be metallic or non-metallic. For example, fan blades 132 can be made of carbon fiber-epoxy composite material or other similar materials. Figure 2 Example fan section 106 includes a fan outlet stator (FES) 204. FES 204 directs a second portion 148 of air 142 into an annular inlet 110 of the LP compressor 112. FES 204 includes an airfoil that directs the second portion 148 of air 142. The airfoil includes a leading edge near the fan blade 132, a trailing edge axially arranged from the leading edge, and a set of two surfaces disposed between the leading and trailing edges. Figure 2 The leading edge of FES 204 is swept axially at an angle S (e.g., not perpendicular to the central axis 102). In some examples, the sweep angle S of the leading edge of FES 204 can range from 0 degrees to 40 degrees rearward. In some examples, the leading edge of FES 204 is not swept axially (e.g., the sweep angle S is zero).

[0030] In some examples, FES 204 is symmetrical (e.g., the two surfaces are symmetrical). In other examples, FES 204 has an outward sag angle (e.g., the two surfaces are asymmetrical). Additionally, the distance between the two surfaces defines the thickness of the airfoil element of FES 204. The distance between the leading and trailing edges of FES 204 defines the chord of FES 204. The sweep angle, outward sag angle, and / or the ratio of the thickness of the airfoil element of FES 204 to the chord can define the shape of FES 204. Although in Figure 2 The example shows a single FES 204, but the example turbo fan (e.g., Figure 1 The turbine fan 100 may include a plurality of circumferentially spaced FES 204s. In some examples, each of the plurality of FES 204s has the same shape (e.g., sweep angle, outward tilt angle, and / or thickness). In other examples, a first portion of the FES 204 has a first shape, while a second portion of the FES 204 has a second shape. In still other examples, each FES 204 of the example turbine fan 100 has a unique shape (e.g., no two FES 204s have the same shape).

[0031] Although Figure 2 Example inlet section 144 includes an FES 204, but the turbo fan (e.g.,Figure 1 The turbine fan 100 of FIG. 1 can include a plurality of circumferentially spaced apart FESs 204. The example inlet portion 144 includes one of the circumferentially spaced apart outlet guide vanes 136. The spinner 208 is joined to the forward end of the rotor disk 202 to provide an aerodynamic flow path for the air 142 entering the fan section 106.

[0032] A reduction gearbox 130 is arranged downstream of the fan section 106. The example reduction gearbox 130 couples the LP shaft 126 and the fan shaft 128 while reducing the speed of the fan shaft 128 relative to the LP shaft 126 by a reduction ratio (e.g., 2: 1, 4: 1, etc.). Radially outward of the reduction gearbox 130 is an example fan frame strut 206. The example fan frame strut 206 is arranged downstream of the FES 204 with an axial gap between the trailing edge of the FES 204 and the leading edge of the fan frame strut 206. The example fan frame strut 206 supports the load of the fan section 106 between the FES 204 and the LP compressor 112. Due to the integration of the reduction gearbox 130, the example inlet portion 144 includes an axial break between the FES 204 and the LP compressor 112. The fan frame strut 206 supports the LP flow path for the second portion 148 of the air 142 between the FES 204 and the LP compressor 112. The example fan frame strut 206 includes an airfoil including a leading edge proximate the trailing edge of the FES 204 and a trailing edge arranged downstream of the leading edge and a set of two surfaces between the leading edge and the trailing edge. In some examples, because the fan frame strut 206 supports the load, the leading edge of the fan frame strut 206 can be substantially perpendicular (e.g., within 5 degrees) to the centerline axis 102.

[0033] In some examples, the fan frame strut 206 is symmetrical (e.g., the two surfaces are symmetrical). In some examples, the fan frame strut has a dihedral angle (e.g., the two surfaces are asymmetrical). Additionally, the distance between the two surfaces defines a thickness of the airfoil of the fan frame strut 206. The distance between the leading edge and the trailing edge of the fan frame strut 206 defines a chord of the fan frame strut 206. The ratio of the dihedral angle and / or the thickness to the chord of the airfoil of the fan frame strut 206 can define the shape of the fan frame strut 206. While a single fan frame strut 206 is shown in the example of FIG. 1, example turbine fans (e.g., turbine fans 100 of FIG. 1) can include a plurality of circumferentially spaced apart fan frame struts 206. Figure 2 Figure 1 ​The turbofan 100 may include a plurality of circumferentially spaced fan frame struts 206. In some examples, each fan frame strut 206 has the same outboard angle and thickness-to-chord ratio (e.g., 10% thickness-to-chord ratio). In other examples, a first portion of the plurality of fan frame struts 206 may have a first outboard angle and a first thickness-to-chord ratio (e.g., 5%), while a second portion of the plurality of fan frame struts 206 has a second outboard angle and a second thickness-to-chord ratio (e.g., 20%). In some examples, the number of fan frame struts 206 in the turbofan (e.g., turbofan 100) is less than the number of FES 204 of the turbofan. An LP compressor 112 is arranged downstream of a reduction gearbox 130, and the LP compressor 112 has axially spaced blades and blade rows whose blades engage with a low-pressure shaft 126.

[0034] Figure 3 It shows that it can be used Figure 1 The example turbine fan 100 shown illustrates a second example inlet portion 300. For comparison, in... Figure 3 The dashed lines are used to show Figure 2 The location of the component in the entrance section 144. Figure 3 The solid lines represent components of the inlet section 300. An example inlet section 300 includes an example integrated FES-fan frame support 302. Figure 3 In the example, the integrated FES-fan frame strut 302 includes an FES portion 303 and a fan frame strut portion 305. The FES portion 303 is adjacent to the fan blade 304, while the fan frame strut portion 305 is located downstream of the FES portion 303. The trailing edge of the FES portion 303 is aerodynamically integrated with the leading edge of the fan frame strut portion 305 of the integrated FES-fan frame strut 302. Thus, the FES portion 303 is aerodynamically integrated with the fan frame strut portion 305. For example, a continuous flow path for a second portion 148 of air 142 exists around the integrated FES-fan frame strut 302. The example integrated FES-fan frame strut 302 includes an aerodynamically continuous set of two surfaces extending from the leading edge (e.g., the leading edge of the FES portion 303) to the trailing edge (e.g., the trailing edge of the fan frame strut portion 305). The set of two surfaces of the example integrated FES-fan frame strut 302 may define the outward tilt angle and thickness of the example integrated FES-fan frame strut 302. Additionally, the outward tilt angle and / or thickness of the example integrated FES-fan frame support 302 can define the shape of the integrated FES-fan frame support 302.

[0035] exist Figure 3In some examples, the FES portion 303 and fan frame support portion 305 of the integrated FES-fan frame support 302 are mechanically integrated. In some examples, the mechanical integration of the integrated FES-fan frame support 302 is separable (e.g., using adhesives, bolts, etc.), allowing the fan section 106 to be separated from components of the core turbine 104 (e.g., LP compressor 112) as needed (e.g., for repair or replacement of components of the fan section 106 and / or the core turbine 104). In other examples, the mechanical integration of the integrated FES-fan frame support 302 is not separable (e.g., welded, monolithic construction, etc.).

[0036] As mentioned above Figure 2 As explained, the inlet portion 144 may include a plurality of FES 204 and a plurality of fan frame struts 206, wherein the number of FES 204 is greater than the number of fan frame struts 206. Figure 3 In the example, each portion of the inlet section 300, which includes fan frame strut 206, alternatively includes one of the integrated FES-fan frame struts 302. Therefore, an example gas turbine engine (e.g., turbofan 100) implementing the inlet section 300 includes multiple integrated FES-fan frame struts 302. However, because the number of FES 204 is greater than the number of fan frame struts 206, only the first portion of the FES 204 is integrated into one of the integrated FES-fan frame struts 302. The second portions of the multiple FES 204 are not integrated with the fan frame struts 206. The following is in conjunction with... Figure 4 Describe this relationship. In some examples, each of the plurality of integrated FES-fan frame supports 302 has the same shape. In other examples, a first portion of the plurality of integrated FES-fan frame supports 302 has a first shape, and a second portion of the plurality of integrated FES-fan frame supports 302 has a second shape. In some examples, each of the example integrated FES-fan frame supports 302 has a unique shape compared to each of the other example integrated FES-fan frame supports 302.

[0037] exist Figure 3 In the example, by integrating each fan frame strut with a portion of the multiple FES 204 into the integrated FES-fan frame strut 302, the axial clearance between the FES 204 and the fan frame strut 206 is eliminated. Therefore, the remaining FES 204 (e.g., a second portion of the multiple FES 204) can be located in... Figure 2 The rear of FES 204 (e.g., downstream of axis A). Due to the rearward positioning of the remaining FES 204, the additional components of the inlet portion 300 can be... Figure 2The corresponding components shown are located at the rear. For example, Figure 3 The fan blades are made of 304 stainless steel. Figure 2 Behind the fan blades 132. Additionally, Figure 3 The reduction gearbox 306 in Figure 2 The rear of the reduction gearbox 130. Due to the rearward positioning of some components of the inlet section 300, the additional components of the inlet section 300 and... Figure 2 The size can be reduced compared to the corresponding parts shown. For example, compared to Figure 2 Compared to the foremost point of LP axis 126, Figure 3 The foremost point of LP shaft 308 is at the rear. As a result, the length of LP shaft 308 is reduced compared to LP shaft 126. Due to the reduced length of LP shaft 308, LP shaft 308 can have a reduced mass compared to LP shaft 126. Furthermore, due to the reduced length of LP shaft 308, the fan housing can also be reduced (e.g., Figure 1 The overall length of the LP shaft 308 (134) is reduced, thereby reducing the overall mass of the gas turbine engine (e.g., turbofan 100). Additionally, due to the reduced length of the LP shaft 308, the LP shaft 308 can have an increased critical frequency (e.g., natural frequency). In some examples, the increased critical frequency of the LP shaft 308 can allow for increased speeds of the gas turbine engine (e.g., turbofan 100). In other examples, the increased critical frequency of the LP shaft 308 can increase the turbofan 100's resistance to engine dynamics and vibration risks.

[0038] because Figure 3 The rearward positioning of the FES 204 at the inlet section 300 provides an additional flow path 310 leading to a bypass airflow passage 140 downstream of the fan section 106. In other words, the duct area downstream of the fan section 106 is increased due to the rearward positioning of the FES 204. As a result of the increased duct area, the air velocity moving through the duct area decreases, and therefore, the frictional losses on the duct surface are also reduced.

[0039] In some examples, the implementation of multiple integrated FES fan frame struts 302 can be combined with one or more other technologies to further reduce mass and / or increase the technical performance of the gas turbine engine (e.g., turbofan 100). For example, fan blades 304 can be implemented with shortened dovetail blade roots, as described in, for example, U.S. Patent Application No. 17 / 535,291 by Zheng et al., the entire contents of which are incorporated herein by reference. By implementing shortened dovetail blade roots, rotor disk 312 can be positioned relative to... Figure 3 Behind the entrance section 300 shown. Therefore, with Figure 2Compared to the fan shaft 128 of the inlet portion 144, the fan shaft 314 can have a reduced length. Due to the reduced length of the fan shaft 314, it can have a reduced mass compared to the fan shaft 128. Furthermore, due to the reduced length of the fan shaft 314, the fan housing (e.g., Figure 1 The total length of the cabin (134) can also be reduced.

[0040] Figure 4 This includes a view 400 showing a portion of the inlet section 300 extending along the circumferential axis C. Example view 400 includes multiple integrated FES-fan frame struts 302 and multiple FES 204. Each of the integrated FES-fan frame struts 302 includes an FES portion 303 and a fan frame strut portion 305. (As described above...) Figure 3 The first portion of the plurality of FES 204s is integrated into the integrated FES-fan frame support 302 as FES portion 303. The second portion of the plurality of FES 204s is not integrated into the integrated FES-fan frame support 302.

[0041] exist Figure 4 In the examples shown, each FES 204 has a unique shape. For example, the sweep angle and / or thickness of each FES 204 is different. Additionally, in Figure 4 In the examples, the shape of the first example integrated FES-fan frame support 302 differs from that of the second example integrated FES-fan frame support 302. For example, the thickness-chord ratio of the second integrated FES-fan frame support 302 is reduced compared to the thickness-chord ratio of the integrated FES-fan frame support 302. Figure 4 View 400 includes only a portion of the multiple integrated FES-fan frame struts 302 and multiple FES 204. For example, the example inlet portion 300 may include a total of six integrated FES-fan frame struts 302. In other examples, the example inlet portion 300 may include more or fewer than six integrated FES-fan frame struts 302. Although Figure 4 The example integrated FES-fan frame support 302 is shown as a single unit, but the FES portion 303 and the fan frame support portion 305 can be mechanically separated, as shown below. Figure 5A , 5B As described in detail with 5C.

[0042] Figure 5AA first example configuration of a joint of a first example integrated FES-fan frame strut 500 is shown. As described above, while it is advantageous to aerodynamically integrate a FES (e.g., FES 204) and a fan frame strut (e.g., fan frame strut 206), it is also advantageous to mechanically decouple the FES 204 and the fan frame strut 206 for repair of a gas turbine engine (e.g., turbofan 100). The first example integrated FES-fan frame strut 500 includes a FES portion 502 and a fan frame strut portion 504. The fan frame strut portion 504 includes a tongue 506 along a leading edge of the fan frame strut portion 504. The tongue 506 is disposed within a cavity 508. The cavity 508 is part of a trailing edge of the FES portion 502. An adhesive 510 is disposed between the tongue 506 and the cavity 508. The example adhesive 510 can be a semi-permanent structural adhesive (e.g., an epoxy adhesive) that provides structural rigidity to the joint of the first example integrated FES-fan frame strut 500 while allowing the FES portion 502 and the fan frame strut portion 504 to be mechanically decoupled.

[0043] Figure 5B A second example configuration of a joint of a second example integrated FES-fan frame strut 512 is shown. The second example integrated FES-fan frame strut 512 includes a FES portion 514 and a fan frame strut portion 516. The fan frame strut portion 516 includes a tongue 518 along a leading edge of the fan frame strut portion 516. The tongue 518 is disposed within a cavity 520. The cavity 520 is part of a trailing edge of the FES portion 514. An adhesive 522 is disposed between a portion of the tongue 518 and the cavity 520. Additionally, a void 524 is retained between the tongue 518 and the cavity 520 of the FES portion 514 when the second example integrated FES-fan frame strut 512 is assembled. The void 524 is an air-filled space that allows for expansion and / or contraction of the FES portion 514 and / or the fan frame strut portion 516 while maintaining the joint of the second example integrated FES-fan frame strut 512 during, for example, operation of a gas turbine engine (e.g., turbofan 100).

[0044] Figure 5C A third example configuration of a joint of a third example integrated FES-fan frame strut 526 is shown. The third example integrated FES-fan frame strut 526 includes a FES portion 528 and a fan frame strut portion 530. The fan frame strut portion 530 includes a tongue 532 along a leading edge of the fan frame strut portion 530. The tongue 532 is disposed within a cavity 534. The cavity 534 is part of a trailing edge of the FES portion 528. An adhesive 536 is disposed between a portion of the tongue 532 and the cavity 534. Additionally, a void 538 is retained between the tongue 532 and the cavity 534 of the FES portion 528 when the third example integrated FES-fan frame strut 526 is assembled. Figure 5CIn the example, the cavity 534 of the FES portion 528 includes a key 536. The example key 536 is disposed within a keyway 538 along a leading edge of the tongue 532 of the fan frame strut portion 530. The example key 536 and the example keyway 538 provide enhanced engagement between the FES portion 528 and the fan frame strut portion 530.

[0045] In some examples, the apparatus includes means for directing air. For example, the means for directing air can be implemented by the FES portion 303. In some examples, the apparatus includes means for supporting a fan section. For example, the means for supporting a fan section can be implemented by the fan frame strut portion 305. In some examples, the apparatus includes means for bonding. For example, the means for bonding can be implemented by the adhesive 510 and / or the adhesive 522. In some examples, the apparatus includes means for receiving. For example, the means for receiving can be implemented by the cavity 508, the cavity 520, and / or the cavity 534. In some examples, the apparatus includes means for assembling. For example, the means for assembling can be implemented by the tongue 506, the tongue 518, and / or the tongue 532. In some examples, the apparatus includes means for expanding. For example, the means for expanding can be implemented by the void 524. In some examples, the apparatus includes means for engaging. For example, the means for engaging can be implemented by the key 536. In some examples, the apparatus includes means for receiving a key. For example, the means for receiving a key can be implemented by the keyway 538.

[0046] From the foregoing, it will be appreciated that example manufactured systems, methods, apparatuses, and articles of manufacture have been disclosed that provide an integrated stator-fan frame assembly that results in a reduction in LP shaft length in a gas turbine engine. The reduction in LP shaft length in the gas turbine engine provides a reduction in engine size and mass while maintaining technical performance (e.g., thrust). Additionally or alternatively, the integrated stator-fan frame assembly can increase a duct region downstream of the fan section. The increased duct region can reduce a flow velocity of air through the duct, thereby reducing duct surface friction losses.

[0047] Example methods, apparatuses, systems, and articles of manufacture implementing an integrated stator-fan frame assembly are disclosed herein. Other examples and combinations thereof include the following:

[0048] Example 1 includes an integrated fan exit stator-fan frame strut assembly for a gas turbine engine, the integrated fan exit stator-fan frame strut assembly comprising: a fan exit stator portion having an airfoil including a leading edge and a trailing edge; a fan frame strut portion including a leading edge and a trailing edge, the leading edge of the fan frame strut portion aerodynamically integrated with the trailing edge of the fan exit stator portion.

[0049] Example 2 includes the integrated fan outlet stator-fan frame strut assembly of any preceding paragraph, further comprising an adhesive disposed between the fan outlet stator portion and the fan frame strut portion.

[0050] Example 3 includes the integrated fan outlet stator-fan frame strut assembly of any preceding paragraph, wherein the fan outlet stator portion is mechanically separable from the fan frame strut portion.

[0051] Example 4 includes the integrated fan outlet stator-fan frame strut assembly of any preceding paragraph, wherein the fan outlet stator portion includes a cavity along a trailing edge of the fan outlet stator portion and the fan frame strut portion includes a tongue along a leading edge of the fan frame strut portion, the tongue disposed within the cavity.

[0052] Example 5 includes the integrated fan outlet stator-fan frame strut assembly of any preceding paragraph, further comprising a void between the tongue and the fan outlet stator portion when the integrated fan outlet stator-fan frame strut assembly is assembled.

[0053] Example 6 includes the integrated fan outlet stator-fan frame strut assembly of any preceding paragraph, wherein the cavity includes a key and the tongue includes a keyway cavity.

[0054] Example 7 includes a fan section of a gas turbine engine, comprising an array of fan blades; an array of fan outlet stators, each fan outlet stator comprising an airfoil having a leading edge and a trailing edge; a plurality of fan frame struts, each fan frame strut comprising a leading edge and a trailing edge, the leading edge of each fan frame strut aerodynamically integrated into the trailing edge of a first portion of the fan outlet stators.

[0055] Example 8 includes the fan section of any preceding paragraph, wherein the leading edge of each fan frame strut is mechanically separable from the trailing edge of the first portion of the fan outlet stators.

[0056] Example 9 includes the fan section of any preceding paragraph, wherein each of the first portion of the fan outlet stators includes a cavity along the trailing edge and each of the fan frame struts includes a tongue along the leading edge, the tongue disposed within the cavity.

[0057] Example 10 includes the fan section of any preceding paragraph, wherein a number of the fan frame struts is less than a number of the fan outlet stators.

[0058] Example 11 includes the fan section of any preceding paragraph, wherein the array of fan outlet stators is axially disposed in a direction of airflow from the array of fan blades and the plurality of fan frame struts is axially disposed in the direction of airflow from the array of fan outlet stators.

[0059] Example 12 includes the fan section of any preceding paragraph, wherein the first portion of the plurality of fan frame struts has a first shape and the second portion of the plurality of fan frame struts has a second shape.

[0060] Example 13 includes the fan section of any preceding paragraph, wherein the gas turbine engine includes a central rotational axis and the leading edge of each fan frame strut is perpendicular to the central rotational axis.

[0061] Example 14 includes a gas turbine comprising a compressor; a combustion section; a turbine; a shaft rotatably coupling the compressor and the turbine; and a fan section comprising an array of fan blades; an array of fan outlet stators, each fan outlet stator comprising an airfoil having a leading edge and a trailing edge; and a plurality of fan frame struts, each fan frame strut comprising a leading edge and a trailing edge, the leading edge of each fan frame strut being aerodynamically integrated into the trailing edge of a first portion of the fan outlet stators.

[0062] Example 15 includes the gas turbine of any preceding paragraph, further comprising a second shaft rotatably coupling the compressor and the fan section, the rotatably coupling the compressor and the fan section comprising a compressor shaft portion and a fan shaft portion.

[0063] Example 16 includes the gas turbine of any preceding paragraph, wherein the gas turbine includes a reduction gearbox to reduce a speed of the fan shaft portion relative to the compressor shaft portion.

[0064] Example 17 includes the gas turbine of any preceding paragraph, wherein the leading edge of each fan frame strut is mechanically separable from the trailing edge of the first portion of the fan outlet stators.

[0065] Example 18 includes the gas turbine of any preceding paragraph, wherein each of the first portion of the fan outlet stators includes a cavity along the trailing edge and each of the plurality of fan frame struts includes a tongue along the leading edge, the tongue disposed within the cavity.

[0066] Example 19 includes the gas turbine of any preceding paragraph, wherein a number of the fan frame struts is less than a number of the fan outlet stators.

[0067] Example 20 includes the gas turbine of any preceding paragraph, wherein the array of fan outlet stators is axially disposed in a direction of airflow from the array of fan blades and the plurality of fan frame struts is axially disposed in the direction of airflow from the array of fan outlet stators.

[0068] Example 21 includes the integrated fan outlet stator-fan frame strut assembly of any preceding paragraph, wherein the leading edge of the fan outlet stator portion is canted.

[0069] Example 22 includes the gas turbine of any preceding paragraph, wherein the gas turbine engine includes a central rotational axis and a leading edge of each fan frame strut is not perpendicular to the central rotational axis.

[0070] Example 23 includes the fan section of any preceding paragraph, wherein each fan blade includes a root attachment portion, a chord length of each fan blade is defined by a distance between a leading edge of the fan blade and a trailing edge of the fan blade, and an axial length of the root attachment portion is less than the chord length.

[0071] Example 24 includes the fan section of any preceding paragraph, wherein a first portion of the fan outlet stator array has a first shape and a second portion of the fan outlet stator array has a second shape.

[0072] Example 25 includes the fan section of any preceding paragraph, wherein a leading edge of at least one fan outlet stator is swept.

[0073] Example 26 includes the fan section of any preceding paragraph, wherein each fan outlet stator of the fan outlet stator array has a unique shape compared to each of the other fan outlet stators of the fan outlet stator array.

[0074] Example 27 includes the fan section of any preceding paragraph, wherein a first portion of the fan outlet stator array has a first out-of-plane angle and a second portion of the fan outlet stator array has a second out-of-plane angle.

[0075] Example 28 includes the fan section of any preceding paragraph, wherein each fan outlet stator of the fan outlet stator array has a unique out-of-plane angle compared to each of the other fan outlet stators of the fan outlet stator array.

[0076] Example 29 includes the fan outlet stator of any preceding paragraph, wherein a first fan outlet stator of the fan outlet stator array has a unique shape compared to a second fan outlet stator radially closest to the first fan outlet stator in a positive direction and a third fan outlet stator radially closest to the first fan outlet stator in a negative direction.

[0077] Example 30 includes the fan outlet stator of any preceding paragraph, wherein a first fan outlet stator of the fan outlet stator array has a unique out-of-plane angle compared to a second fan outlet stator radially closest to the first fan outlet stator in a positive direction and a third fan outlet stator radially closest to the first fan outlet stator in a negative direction.

[0078] The following claims are hereby incorporated by reference into this DETAILED DESCRIPTION. Although certain example manufactured systems, methods, apparatuses, and articles of manufacture have been disclosed herein, the scope of coverage of this patent can not be limited to what is disclosed. Rather, this patent covers all manufactured systems, methods, apparatuses, and articles of manufacture that fall within the scope of the claims.

Claims

1. An integrated fan exit stator - fan frame strut assembly for a gas turbine engine, characterized by, The integrated fan outlet stator-fan frame strut assembly includes: a fan outlet stator portion having an airfoil including a first leading edge and a first trailing edge; and a fan frame strut portion including a second leading edge and a second trailing edge, the second leading edge of the fan frame strut portion aerodynamically integrated with the first trailing edge of the fan outlet stator portion; a pressure surface defined on a first side between the first leading edge and the second trailing edge of the fan outlet stator portion and the fan frame strut portion; and a suction surface defined on a second side opposite the first side; an adhesive disposed between the fan outlet stator portion and the fan frame strut portion, the adhesive separated from the pressure surface and the suction surface by the fan outlet stator portion or the fan frame strut portion.

2. The integrated fan outlet stator-fan frame strut assembly of claim 1, wherein, wherein the fan outlet stator portion is mechanically separable from the fan frame strut portion.

3. The integrated fan outlet stator-fan frame strut assembly of claim 1, wherein, wherein the fan outlet stator portion includes a cavity along the first trailing edge of the fan outlet stator portion and the fan frame strut portion includes a tongue along the second leading edge of the fan frame strut portion, the tongue disposed within the cavity.

4. The integrated fan outlet stator-fan frame strut assembly of claim 3, wherein, further comprising a void between the tongue and the fan outlet stator portion when the integrated fan outlet stator-fan frame strut assembly is assembled.

5. The integrated fan outlet stator - fan frame strut assembly of claim 4, wherein, wherein, the cavity includes a key and the tongue includes a keyway cavity.

6. A fan section of a gas turbine engine, characterized by, including: an array of fan blades; an array of fan outlet stators, each of the fan outlet stators including an airfoil including a first leading edge and a first trailing edge; and a plurality of fan frame struts, each of the fan frame struts including a second leading edge and a second trailing edge, the second leading edge of each of the fan frame struts aerodynamically integrated into the first trailing edge of the first portion of the fan outlet stators; a pressure surface defined on a first side between the first leading edge and the second trailing edge of the portions of the fan outlet stators and the fan frame struts; a suction surface defined on a second side opposite the first side; an adhesive disposed between the portions of the fan outlet stators and the portions of the fan frame struts, the adhesive separated from the pressure surface and the suction surface by the portions of the fan outlet stators or the portions of the fan frame struts.

7. The fan section of claim 6, wherein, wherein the second leading edge of each of the fan frame struts is mechanically separable from the first trailing edge of the first portion of the fan outlet stators.

8. The fan section of claim 6, wherein, wherein each of the first portions of the fan outlet stators includes a cavity along the first trailing edge and each of the fan frame struts includes a tongue along the second leading edge, the tongue disposed within the cavity.

9. The fan section of claim 6, wherein, wherein the number of the fan frame struts is less than the number of the fan outlet stators.

10. The fan section of claim 6, wherein, wherein the fan outlet stator array is arranged axially in a direction of airflow from the fan blade array, and the plurality of fan frame struts are arranged axially in the direction of airflow from the fan outlet stator array.

11. The fan section of claim 6, wherein, wherein a first portion of the plurality of fan frame struts has a first shape, and a second portion of the plurality of fan frame struts has a second shape.

12. The fan section of claim 6, wherein, wherein a first portion of the fan outlet stator array has a first shape, and a second portion of the fan outlet stator array has a second shape.

13. A gas turbine characterized by, comprising: a compressor; a combustion section; a turbine; a shaft rotatably coupling the compressor and the turbine; and a fan section comprising: a fan blade array; a fan outlet stator array, each of the fan outlet stators comprising an airfoil comprising a first leading edge and a first trailing edge; and a plurality of fan frame struts, each of the fan frame struts comprising a second leading edge and a second trailing edge, the second leading edge of each of the fan frame struts being aerodynamically integrated into the first trailing edge of a first portion of the fan outlet stators; a pressure surface defined on a first side between the first leading edge and the second trailing edge of the portion of the fan outlet stators and the portion of the fan frame struts; and a suction surface defined on a second side opposite the first side; an adhesive disposed between the portion of the fan outlet stators and the portion of the fan frame struts, the adhesive being separated from the pressure surface and the suction surface by the portion of the fan outlet stators or the portion of the fan frame struts.

14. The gas turbine of claim 13, characterized in that further comprising a second shaft rotatably coupling the compressor and the fan section, the second shaft rotatably coupling the compressor and the fan section comprising a compressor shaft portion and a fan shaft portion.

15. The gas turbine of claim 14, wherein, wherein the gas turbine comprises a reduction gear box to reduce a speed of the fan shaft portion relative to the compressor shaft portion.

16. The gas turbine of claim 13, wherein, wherein the second leading edge of each of the fan frame struts is mechanically separable from the first trailing edge of the first portion of the fan outlet stators.

17. The gas turbine of claim 13, wherein, wherein each of the first portions of the fan outlet stators comprises a cavity along the first trailing edge, and each of the fan frame struts comprises a tongue along the second leading edge, the tongue being arranged within the cavity.

18. The gas turbine of claim 13, wherein, wherein a number of the fan frame struts is less than a number of the fan outlet stators.

19. The gas turbine of claim 13, wherein, wherein the fan outlet stator array is arranged axially in a direction of airflow from the fan blade array, and the plurality of fan frame struts are arranged axially in the direction of airflow from the fan outlet stator array. wherein the fan outlet stator array is arranged axially in a direction of airflow from the fan blade array, and the plurality of fan frame struts are arranged axially in the direction of airflow from the fan outlet stator array.

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