Composite airfoil assembly having a composite airfoil and a spar

Abstract

A composite airfoil assembly having a composite airfoil, a spar, and a wrap. The composite airfoil has an outer wall and a composite skin. The outer wall extends between a root and a tip. The outer wall defines an interior. The composite skin at least partially defines the outer wall. The spar has a spar centerline axis, a shank, a base, and a transition interconnecting the base and the shank.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to Indian Patent Application Serial No. 202411010190, filed on February 14, 2024, which is incorporated herein by reference in its entirety. Technical Field

[0003] This disclosure generally relates to composite airfoil assemblies, and more specifically, to composite airfoil assemblies having composite airfoils and spars. Background Technology

[0004] Turbine engines (and particularly gas or combustion turbine engines) are rotary engines that extract energy from a stream of gas that passes through a fan with multiple fan blades, then through a series of compressor stages (which consist of pairs of rotating blades and stationary blades), through a combustor, and then through a series of turbine stages (which also consist of pairs of rotating blades and stationary blades) into the engine. The blades are mounted to a rotating disk, while the blades are mounted to a stator disk.

[0005] During operation, air enters the compressor section through the fan section, is then pressurized in the compressor, and mixed with fuel in the combustor and ignited to generate hot combustion gases. These hot combustion gases flow downstream through the turbine stage, where the air expands and exits through the exhaust section. The expansion of air in the turbine section drives the rotating sections of the fan and compressor sections. The intake, pressurization, and expansion of air are accomplished to a certain extent by the rotation of various rotating blades on corresponding disks mounted to the fan, compressor, and turbine sections, respectively. The rotation of the blades applies mechanical stress along various portions of the blades; particularly along the points where the blades are mounted to the disks. Attached Figure Description

[0006] The complete and feasible disclosure of this disclosure, including its best mode, is set forth in the specification with reference to the accompanying drawings, for those skilled in the art, wherein:

[0007] Figure 1 This is a schematic cross-sectional view of a turbine engine, which is a non-pipeline or open rotor turbine engine according to exemplary embodiments of the present disclosure.

[0008] Figure 2 Is it suitable for Figure 1 A schematic diagram of a composite airfoil assembly used in a turbine engine, which includes a composite airfoil, trunnions, spars, and enclosure.

[0009] Figure 3 From Figure 2Section line III-III shows a schematic cross-sectional view of a portion of the composite airfoil assembly, further illustrating the shank and base of the spar, with a transition section disposed between the shank and base, an enclosure disposed on the transition section, and the spar having a centerline axis.

[0010] Figure 4 This is seen from a plane extending along the centerline axis of the wing spars. Figure 3 A schematic cross-sectional view of half of the package, further showing a first region with a first thickness and a second region with a second thickness.

[0011] Figure 5 It is seen along a plane extending circumferentially relative to the centerline axis. Figure 3 The diagram shows the package, which has been flattened, and further illustrates a second area that defines the perimeter of the package.

[0012] Figure 6 yes Figure 2 A bottom-up perspective view of the composite airfoil assembly further illustrates the gap formed between the opposite ends of the package.

[0013] Figure 7 It is suitable for use as Figure 2 A top-down cross-sectional view of an exemplary airfoil assembly of a composite airfoil assembly further illustrates the enclosure including a first body and a second body.

[0014] Figure 8 It is suitable for use as Figure 2 A top-down cross-sectional view of an exemplary airfoil assembly of a composite airfoil assembly further illustrates the enclosure including a continuous body.

[0015] Figure 9 It is suitable for use as Figure 2 A schematic cross-sectional view of a portion of an exemplary airfoil assembly, further including a composite airfoil having a composite skin and wrappings disposed on corresponding portions of the composite skin.

[0016] Figure 10 It is suitable for use as Figure 2 A schematic cross-sectional view of a portion of an exemplary airfoil component of a composite airfoil component assembly, further including a wrapper and a second wrapper. Detailed Implementation

[0017] The aspects disclosed herein relate to a composite airfoil assembly for a turbine engine. The composite airfoil assembly includes a composite airfoil, a spars, a trunnion, and a shroud. The spars include a shank and a base extending from the shank. The spars include a transition section extending between the shank and the base. The shroud at least partially surrounds the transition section. The shroud can be used to reinforce the composite airfoil assembly along the transition section.

[0018] For illustrative purposes, this disclosure is described in relation to composite airfoil assemblies for turbine engines, particularly fan blades of turbine engines. However, it will be understood that the aspects of this disclosure described herein are not limited thereto and may have general applicability in other engines or other parts of turbine engines. For example, this disclosure may be applied to composite airfoil assemblies in other engines or vehicles and may provide benefits in industrial, commercial, and residential applications.

[0019] As used herein, the term "upstream" refers to the direction opposite to the direction of fluid flow, while the term "downstream" refers to the direction in the same direction as the fluid flow. The terms "front" or "in front" indicate what is in front of something, and "back" or "behind" indicate what is behind something. For example, when used in relation to fluid flow, "front" or "in front" can indicate upstream, and "back" or "behind" can indicate downstream.

[0020] Additionally, as used herein, the terms "axial" and "longitudinal" refer to directions parallel to the central axis of an object, while the terms "radial" or "radially" refer to directions perpendicular to the axial direction or away from the common center. For example, in the overall context of a turbine engine, radial refers to the direction of a ray extending between the engine's central longitudinal axis and the engine's outer perimeter. Furthermore, as used herein, the term "group" or a "set" of elements can be any number of elements, including only one.

[0021] Furthermore, as used herein, the term "fluid" or its iterations may refer to any suitable fluid within a gas turbine engine, at least a portion of which is exposed to, for example, but not limited to, combustion gases, ambient air, pressurized airflow, operating airflow, or any combination thereof. Further contemplation suggests that the gas turbine engine may be another suitable turbine engine, such as, but not limited to, a steam turbine engine or a supercritical carbon dioxide turbine engine. As a non-limiting example, the term "fluid" may refer to steam in a steam turbine engine or carbon dioxide in a supercritical carbon dioxide turbine engine.

[0022] All directional references (e.g., radial, axial, proximal, distal, up, down, upward, downward, left, right, lateral, front, rear, top, bottom, above, below, vertical, horizontal, clockwise, counterclockwise, upstream, downstream, forward, backward, etc.) are used for identification purposes only to aid the reader in understanding this disclosure and do not impose limitations, particularly regarding the location, orientation, or use of the aspects of the disclosure described herein. Connecting references (e.g., attachment, connection, fixation, fastening, joining, and engagement) are to be interpreted broadly and may include intermediate members between sets of elements and relative movement between elements, unless otherwise indicated. Therefore, a connecting reference does not necessarily mean that two elements are directly connected and fixed relative to each other. Exemplary figures are for illustrative purposes only, and the dimensions, positions, order, and relative sizes reflected in the accompanying figures may vary.

[0023] As used herein, the term "composite" refers to a component having two or more materials. A composite can be a combination of at least two or more metals, nonmetals, or metal and nonmetal elements or materials. Examples of composite materials can be, but are not limited to, polymer matrix composites (PMCs), ceramic matrix composites (CMCs), metal matrix composites (MMCs), carbon fibers, polymeric resins, thermoplastic resins, bismaleimide (BMI) materials, polyimide materials, epoxy resins, glass fibers, and silicon matrix materials.

[0024] As used herein, a "composite" component refers to a structure or component comprising any suitable composite material. A composite component (e.g., a composite airfoil) may comprise several layers or several plies of composite material. The stiffness, material, and dimensions of the layers or plies may vary to achieve a desired composite component or composite portion of a component having a predetermined weight, size, stiffness, and strength.

[0025] One or more adhesive layers may be used to form or join composite components. The adhesive may include resins and phenolic resins, where the adhesive may require curing at elevated temperatures or other hardening techniques.

[0026] As used herein, PMC refers to a class of materials. As an example, PMC materials are partially defined by prepregs, which are reinforcing materials pre-impregnated with a polymer matrix material (e.g., a thermoplastic resin). Non-limiting examples of processes used to produce thermoplastic prepregs include: hot melt prepreg, in which the fiber reinforcement is drawn through a molten bath of resin; and powder prepreg, in which the resin is deposited onto the fiber reinforcement, as a non-limiting example, electrostatically deposited onto the fiber reinforcement, and then adhered to the fibers, as a non-limiting example, in an oven or with the aid of heated rollers. The prepregs may be in the form of unidirectional tapes or woven fabrics, which are then stacked on top of each other to form the desired number of layups for the part.

[0027] Multilayer prepregs are stacked to the appropriate thickness and orientation of the composite part, and then the resin is cured and solidified to provide fiber-reinforced composite parts. Resins used for PMC matrix materials are generally classified as thermosetting or thermoplastic resins. Thermoplastic resins are generally classified as polymers that can repeatedly soften and flow upon heating and harden upon sufficient cooling due to physical rather than chemical changes. Well-known examples of thermoplastic resins include nylon, thermoplastic polyesters, polyaryletherketones (PAEKs), and polycarbonate resins. Specific examples of high-performance thermoplastic resins envisioned for aerospace applications include polyetheretherketone (PEEK), polyetherketoneketone (PEKK), polyetherimide (PEI), polyaryletherketone (PAEK), and polyphenylene sulfide (PPS). In contrast, thermosetting resins do not undergo significant softening upon heating once fully cured into a rigid solid, but rather thermally decompose upon sufficient heating. Well-known examples of thermosetting resins include epoxy resins, bismaleimide (BMI), and polyimide resins.

[0028] Instead of using prepreg, in another non-limiting example, woven fabrics can be utilized by using thermoplastic polymers. Woven fabrics may include, but are not limited to, dry carbon fibers woven together with thermoplastic polymer fibers or filaments. Non-prepreg braided structures can be fabricated in a similar manner. With this method, the fiber volume of the part can be customized by specifying the relative concentrations of the woven or braided thermoplastic fibers and reinforcing fibers. Furthermore, different types of reinforcing fibers can be braided or woven together at different concentrations to customize the properties of the part. For example, glass fibers, carbon fibers, and thermoplastic fibers can all be woven together at different concentrations to customize the properties of the part. Carbon fibers provide the strength of the system, can be incorporated into glass fibers to enhance impact characteristics—a design feature of parts located near the engine inlet—and thermoplastic fibers provide bonding for the reinforcing fibers.

[0029] In yet another non-limiting example, resin transfer molding (RTM) can be used to form at least a portion of a composite part. Typically, RTM involves applying a dry fiber or matrix material to a mold or cavity. The dry fiber or matrix material may include prepreg, woven material, braided material, or any combination thereof.

[0030] Resin can be pumped into or otherwise supplied to a mold or cavity to impregnate dry fibers or matrix material. The impregnated fibers or matrix material, combined with the resin, is then cured and removed from the mold. Post-curing may be required when removing the composite component from the mold.

[0031] It is conceivable that RTM could be a vacuum-assisted process. That is, air in the cavity or mold can be removed and replaced with resin before heating or curing. It is further conceivable that the placement of dry fibers or matrix material can be manual or automatic. As a non-limiting example, the placement of dry fibers or matrix material can be accomplished either automatically (AFP) or manually.

[0032] Dry fibers or matrix materials can be molded to form composite components or guide resins. Optionally, additional layers or reinforcing layers of materials different from the dry fibers or matrix materials may be included or added prior to heating or curing.

[0033] As used herein, CMC refers to a class of materials having reinforcing fibers within a ceramic matrix. Typically, the reinforcing fibers provide structural integrity to the ceramic matrix. Some examples of reinforcing fibers may include, but are not limited to, non-oxide silicon-based materials (e.g., silicon carbide, silicon nitride, or mixtures thereof), non-oxide carbon-based materials (e.g., carbon), oxide ceramics (e.g., silicon oxycarbide, silicon oxynitride, alumina (Al₂O₃), silicon dioxide (SiO₂), aluminosilicates (such as mullite), or mixtures thereof), or mixtures thereof.

[0034] Examples of ceramic matrix materials may include, but are not limited to, non-oxide silicon-based materials (e.g., silicon carbide, silicon nitride, or mixtures thereof), oxide ceramics (e.g., silicon oxycarbide, silicon oxynitride, alumina (Al₂O₃), silicon dioxide (SiO₂), aluminosilicates, or mixtures thereof), or mixtures thereof. Optionally, ceramic particles (e.g., oxides of Si, Al, Zr, Y, and combinations thereof) and inorganic fillers (e.g., pyrophyllite, wollastonite, mica, talc, kyanite, and montmorillonite) may also be included within the ceramic matrix.

[0035] Typically, a particular CMC can be referred to as a combination of its fiber type / matrix type. For example, C / SiC is carbon fiber reinforced silicon carbide; SiC / SiC is silicon carbide fiber reinforced silicon carbide; SiC / SiN is silicon carbide fiber reinforced silicon nitride; SiC / SiC-SiN is a silicon carbide fiber-reinforced silicon carbide / silicon nitride matrix mixture, etc. In other examples, a CMC may consist of a matrix comprising an oxide-based material (such as alumina (Al₂O₃), silicon dioxide (SiO₂), aluminosilicates, and mixtures thereof) and reinforcing fibers. Aluminosilicates may include crystalline materials (e.g., mullite (3Al₂O₃·2SiO₂)) as well as glassy aluminosilicates.

[0036] In some non-limiting examples, the reinforcing fibers may be bundled and / or coated before being incorporated into the matrix. For example, the fiber bundles may be formed as reinforcing tapes, such as unidirectional reinforcing tapes. Multiple tapes may be stacked together to form a preform component. The fiber bundles may be impregnated with a slurry composition before or after the formation of the preform. The preform may then undergo heat treatment and subsequent chemical treatment to obtain a component formed from a CMC material having a desired chemical composition. For example, the preform may undergo curing or burnout to produce a high coke residue in the preform and subsequently melt infiltration with silicon, or undergo curing or pyrolysis to produce a silicon carbide matrix in the preform and subsequently chemical vapor infiltration with silicon carbide. Additional steps may be taken to enhance the densification of the preform, either before or after chemical vapor infiltration, by injecting the preform with a liquid resin or polymer and then performing a heat treatment step to fill the voids with silicon carbide. The CMC materials used herein can be formed using any known or later developed methods (including, but not limited to, melt infiltration, chemical vapor infiltration, polymer impregnation pyrolysis (PIP), or any combination thereof).

[0037] These materials, along with certain monolithic ceramics (i.e., ceramic materials without reinforcement), are particularly well-suited for higher-temperature applications. Furthermore, these ceramic materials are lighter than superalloys while still providing strength and durability for components made from them. Therefore, the use of such materials in many gas turbine components used in the higher-temperature range of gas turbine engines (such as airfoils (e.g., turbine and blades), combustors, shields, etc.) is currently being considered, as they will benefit from the lighter weight and higher-temperature capabilities these materials can offer.

[0038] As used herein, the term "metal" refers to materials that include metals (such as, but not limited to, titanium, iron, aluminum, stainless steel, and nickel alloys). Metallic materials or alloys can be combinations of at least two or more elements or materials, at least one of which is a metal.

[0039] Figure 1This is a schematic cross-sectional view of a turbine engine, particularly an open rotor or non-ducted turbine engine 10 for use in aircraft. The non-ducted turbine engine 10 has a generally longitudinally extending axis or engine centerline 12 extending from a front end 14 to a rear end 16. The non-ducted turbine engine 10 includes a set of circumferentially spaced blades or propellers in a downstream series flow relationship, defining: a fan section 18 including a fan 20; a compressor section 22 including a supercharger or low-pressure (LP) compressor 24 and a high-pressure (HP) compressor 26; a combustion section 28 including a combustor 30; a turbine section 32 including an HP turbine 34 and an LP turbine 36; and an exhaust section 38. The non-ducted turbine engine 10 described herein is a non-limiting example, and other architectures are possible, such as, but not limited to, steam turbine engines, supercritical carbon dioxide turbine engines, or any other suitable turbine engine.

[0040] The outer surface of the non-ducted turbine engine 10, defined by the casing or nacelle 40, extends from the front end 14 of the non-ducted turbine engine 10 toward the rear end 16 of the non-ducted turbine engine 10, and covers at least a portion of the compressor section 22, combustion section 28, turbine section 32, and exhaust section 38. A fan section 18 may be located at the front of the nacelle 40 and extends radially outward from the nacelle 40 of the non-ducted turbine engine 10. Specifically, the fan section 18 extends radially outward from the nacelle 40. The fan section 18 includes a set of fan blades 42 and a set of stationary fan blades 82 downstream of the set of fan blades 42, both radially arranged from and circumferentially arranged around the engine centerline 12. The set of fan blades 42 and the set of stationary fan blades 82 extend radially outward from corresponding portions of the nacelle 40. Thus, the set of fan blades 42 and the set of stationary fan blades 82 may be defined as an outer set of fan blades and an outer set of stationary fan blades 82, respectively. The non-ducted turbine engine 10 includes any number of sets of rotating blades or propellers (e.g., the set of fan blades 42) disposed upstream of the set of stationary fan blades 82. As a non-limiting example, the non-ducted turbine engine 10 may include multiple sets of fan blades 42 or stationary fan blades 82. Therefore, the non-ducted turbine engine 10 is further defined as a non-ducted single-fan turbine engine. The non-ducted turbine engine 10 is further defined by the position of the fan section 18 relative to the combustion section 28. The fan section 18 may be upstream, downstream, or axially aligned with the combustion section 28.

[0041] The compressor section 22, combustion section 28, and turbine section 32 are collectively referred to as the engine core 44, which generates combustion gases. The engine core 44 is surrounded by an engine housing 46, which is operatively connected to a portion of the nacelle 40 of the non-ducted turbine engine 10.

[0042] An HP shaft or spool 48, coaxially arranged about the engine centerline 12 of the non-ducted turbine engine 10, drives the HP turbine 34 to the HP compressor 26. An LP shaft or spool 50, coaxially arranged within a larger diameter annular HP spool 48 about the engine centerline 12 of the non-ducted turbine engine 10, drives the LP turbine 36 to the LP compressor 24 and the fan 20. The spools 48 and 50 are rotatable about the engine centerline 12 and are connected to a set of rotatable elements that collectively define a rotor 51.

[0043] It should be understood that the non-pipeline turbine engine 10 is a direct drive or integral drive engine that utilizes a reduction gearbox that connects the LP shaft or spool 50 to the fan 20.

[0044] LP compressor 24 and HP compressor 26 each include a set of compressor stages 52 and 54, respectively, in which a set of compressor blades 56 and 58 rotate relative to a corresponding set of static compressor impeller blades 60 and 62 (also referred to as nozzles) to compress or pressurize the fluid flow passing through the stage. In a single compressor stage 52 or 54, multiple compressor blades 56 and 58 are arranged in a ring and extend radially outward from the blade platform relative to the engine centerline 12 to the blade tips, while the corresponding static compressor impeller blades 60 and 62 are positioned upstream of and adjacent to the compressor blades 56 and 58. It is worth noting that... Figure 1 The number of blades, impellers, and compressor stages shown is selected for illustrative purposes only, and other numbers are also possible.

[0045] The compressor blades 56, 58 for the first stage of compressor section 22 are mounted to disc 61, which is mounted to a corresponding one of HP spool 48 and LP spool 50, with each stage having its own disc 61. The static compressor blades 60, 62 for the first stage of compressor section 22 are mounted to the engine housing 46 in a circumferential arrangement.

[0046] HP turbine 34 and LP turbine 36 each comprise a set of turbine stages 64 and 66, respectively, in which a set of turbine blades 68 and 70 rotate relative to a corresponding set of static turbine blades 72 and 74 (also referred to as nozzles) to extract energy from the fluid flow passing through the stage. In a single turbine stage 64 and 66, multiple turbine blades 68 and 70 are arranged in a ring and extend radially outward from the blade platform relative to the engine centerline 12 to the blade tips, while the corresponding static turbine blades 72 and 74 are positioned upstream of and adjacent to the turbine blades 68 and 70. It is worth noting that... Figure 1 The number of blades, impellers, and turbine stages shown is selected for illustrative purposes only; other numbers are also possible.

[0047] Turbine blades 68, 70 for the first stage of turbine section 32 are mounted to disc 71, which is mounted to a corresponding one of HP spool 48 and LP spool 50, with each stage having a dedicated disc 71. Static turbine blades 72, 74 for the first stage of turbine section 32 are mounted to engine housing 46 in a circumferential arrangement.

[0048] The rotating parts of the non-piped turbine engine 10 (e.g., blades 56, 58, 68, 70 in the compressor section 22 and turbine section 32) are also referred to individually or collectively as rotor 51. Therefore, rotor 51 refers to the combination of rotating elements throughout the non-piped turbine engine 10.

[0049] Complementing the rotating parts, the stationary parts of the non-ducted turbine engine 10 (e.g., the static blades 60, 62, 72, 74 in the compressor section 22 and the turbine section 32) are also referred to individually or collectively as the stator 63. Therefore, the stator 63 refers to the combination of non-rotating elements throughout the non-ducted turbine engine 10.

[0050] The nacelle 40 is operatively coupled to the non-ducted turbine engine 10 and covers at least a portion of the engine core 44, engine casing 46, or exhaust section 38. At least a portion of the nacelle 40 extends axially forward or upstream at the indicated location. For example, the nacelle 40 extends axially forward such that a portion of the nacelle 40 covers or conceals a portion of the fan section 18 or supercharger section (not shown) of the non-ducted turbine engine 10. The turbine engine includes a pylon 84. The pylon 84 mounts the turbine engine 10 to an external structure (e.g., the fuselage, wings, tail, etc. of an aircraft).

[0051] It should be understood that the non-ducting turbine engine 10 can be divided into at least two separate parts: a rotor part and a stator part. The rotor part can be defined as any portion of the non-ducting turbine engine 10 that rotates about a corresponding axis of rotation. The stator part can be defined by a combination of non-rotating elements disposed within the non-ducting turbine engine 10. As a non-limiting example, the rotor part may include a plurality of fan blades 42, compressor blades 56, 58, or turbine blades 68, 70. As a non-limiting example, the stator part may include a plurality of fan blades 82, static compressor blades 60, 62, or static turbine blades 72, 74.

[0052] During operation of the non-ducted turbine engine 10, a free-flowing airflow 80 flows against the front of the non-ducted turbine engine 10. A first portion of the free-flowing airflow 80, as an external airflow 78, flows along the nacelle 40 and over the set of stationary fan blades 82. The external airflow 78 follows the curvature of the nacelle 40 and flows toward the exhaust section 38 over the set of stationary fan blades 82. A second portion of the free-flowing airflow 80 enters an annular region 25 defined by a swept area between the outer surface of the nacelle 40 and the tips of the fan blades 42, where this airflow is the inlet airflow 76. A portion of the inlet airflow 76 enters the engine core 44 and is described as inlet airflow 76, which is used for combustion within the engine core 44.

[0053] More specifically, the working airflow 76 flows into the LP compressor 24, which then pressurizes the working airflow 76, thereby defining a pressurized airflow supplied to the HP compressor 26, which further pressurizes the air. The working airflow 76 or pressurized airflow from the HP compressor 26 mixes with and ignites fuel in the combustor 30, thereby generating combustion gases. The HP turbine 34 extracts some work from these gases, which drives the HP compressor 26. The combustion gases are discharged into the LP turbine 36, which extracts additional work to drive the LP compressor 24, and the working airflow 76 or exhaust gas is finally discharged from the inline turbine engine 10 via the exhaust section 38. The drive of the LP turbine 36 drives the LP spool 50 to rotate the fan 20 and the LP compressor 24. The working airflow 76, comprising the pressurized airflow and combustion gases, defines the working airflow flowing through the compressor section 22, the combustion section 28, and the turbine section 32 of the inline turbine engine 10.

[0054] The working airflow 76 and at least some external airflows 78 converge downstream of the exhaust section 38 of the non-ducted turbine engine 10. The working airflow 76 and the external airflows 78 together form the total thrust of the non-ducted turbine engine 10.

[0055] Imagine a portion of the working airflow 76 is drawn as bleed air 77 (e.g., from compressor section 22). Bleed air 77 supplies airflow to engine components requiring cooling. The temperature of the working airflow 76 exiting the combustor 30 is significantly higher than that of the working airflow 76 within compressor section 22. Therefore, cooling provided by bleed air 77 is necessary for operating these engine components in elevated temperature environments or in the hot sections of the non-ducted turbine engine 10. In the case of a turbine engine, the hot sections of the engine are typically downstream of the combustor 30, particularly the turbine section 32, where the HP turbine 34 is the hottest section because it is directly downstream of the combustion section 28. Other sources of cooling fluid are, but are not limited to, fluids discharged from the LP compressor 24 or the HP compressor 26.

[0056] Figure 2Is it suitable for Figure 1 A schematic diagram of a compound airfoil assembly 130 used within a non-ducted turbine engine 10. The compound airfoil assembly 130 includes a compound airfoil 132, which is any suitable airfoil of the turbine engine 10. The compound airfoil assembly 130 may be disposed within the rotor or stator portion of the non-ducted turbine engine 10. As a non-limiting example, the compound airfoil 132 may be a blade among a plurality of fan blades 42, or a blade from compressor blades 56, 58 or turbine blades 68, 70. Where the compound airfoil 132 is a blade, the compound airfoil assembly 130 may be disposed within the rotor portion of the turbine engine 10. It is contemplated that the compound airfoil 132 may be a blade, impeller, airfoil, or other component of any turbine engine (e.g., but not limited to, a gas turbine engine, a turboprop engine, a turboshaft engine, a ducted turbofan engine, the non-ducted turbine engine 10, or an open rotor turbine engine).

[0057] The composite airfoil 132 includes an outer wall 138 defining an interior 148. The outer wall 138 extends between a leading edge 144 and a trailing edge 146 to define a chordal direction (C). The outer wall 138 further extends between a root 140 and a tip 142 to define a spanwise direction (S). The outer wall 138 may be a composite wall made of one or more layers of composite material. The one or more layers of material may be applied during the same or different stages of the manufacture of the composite airfoil 132.

[0058] At least a portion of the composite airfoil 132 may include a composite material. As a non-limiting example, the outer wall 138, the spar 136, or combinations thereof may include at least a PMC portion, a polymer portion, or both. The PMC portion may include, but is not limited to, a thermosetting matrix (epoxy resin, phenolic resin) or a thermoplastic matrix (polycarbonate, polyvinyl chloride, nylon, acrylic resin), and embedded glass, carbon, steel, or combinations thereof. It should be understood that the composite airfoil 132 may include composite materials, non-composite metallic materials, any other suitable materials, or combinations thereof.

[0059] The composite airfoil assembly 130 includes a sparsity 136 and a trunnion 134. The sparsity 136 extends into the interior 148 and is coupled to the airfoil 132 by any suitable method. The sparsity 136 extends from the root 140. The sparsity 136 is operatively coupled to the trunnion 134 (e.g., by bonding, adhesion, fastening, or any other suitable coupling method). The trunnion 134 comprises any suitable material, such as, but not limited to, metallic materials or composite materials. It should be understood that the term composite material can further include metals having a composite structure (e.g., a metal matrix composite). In the case of composite materials, the trunnion 134 can be any suitable composite material, such as 2D or 3D composite materials, laminated composite skins, woven or braided composite materials, or any other suitable composite material.

[0060] The composite airfoil 132 has a span length (L) measured along the span direction (S) from its root 140 at 0% of the span length (L) to its tip 142 at 100% of the span length (L). The entire spar 136 may be located below 20% of the span length (L). Alternatively, the spar 136 may extend beyond 20% of the span length (L).

[0061] The composite airfoil assembly 130 includes an envelope 150 disposed along a corresponding portion of at least the spars 136. The envelope 150 may comprise any suitable material. As a non-limiting example, the envelope 150 may comprise a composite material, such that the envelope 150 is a composite envelope. As a non-limiting example, the envelope 150 may comprise a metallic material, such that the envelope 150 is a metallic envelope.

[0062] The package 150 may be formed of a single layer of material or multiple materials (such as multiple stacked materials). As a non-limiting example, the package 150 may include a metallic material defining a single layer of material disposed along the composite airfoil assembly 130. As a non-limiting example, the package 150 may include a composite material that surrounds corresponding portions of the composite airfoil assembly 130 multiple times to define multiple stacked composite layers.

[0063] During operation of the compound airfoil assembly 130, the trunnion 134 can rotate in the direction of rotation (Rd) about the pitch axis (Pax). When the spars 136 connects the trunnion 134 to the compound airfoil 132, the rotation of the trunnion 134 in the direction of rotation (Rd) causes the compound airfoil 132 to rotate about the pitch axis (Pax). This rotation can be used to control the pitch of the compound airfoil assembly 130, thereby defining the compound airfoil assembly 130 as a compound variable pitch airfoil assembly. The pitch of the compound airfoil assembly 130 can be based on the turbine engine mounted on the compound airfoil assembly 130 (e.g., Figure 1The operation or expected operation of the turbine engine 10 varies. The working airflow (Fw) flows through the corresponding portion of the composite airfoil assembly 130, specifically through the composite airfoil 132.

[0064] Figure 3 From Figure 2 A schematic cross-sectional view of a portion of the composite airfoil assembly 130, as seen from section line III-III. The spar 136 includes a spar centerline axis 164. The spar 136 includes a shank 158 and a base 160 interconnected by a transition portion 162. The base 160 extends into a corresponding portion of the trunnion 134. The shank 158 extends into the interior 148 of the composite airfoil 132. Figure 2 In the 132, the handle 158 and the base 160 are defined relative to the airfoil 132. As a non-limiting example, most of the handle 158 is disposed within the interior 148, while most of the base 160 is disposed outside the interior 148.

[0065] The composite airfoil 132 includes a composite skin 152. The composite skin 152 defines any suitable portion of the composite airfoil 132. As a non-limiting example, the composite skin 152 may define an outer wall 138 of the composite airfoil 132. Figure 2 At least a portion of the composite airfoil 132. The composite airfoil 132 includes a suction side 15 and an opposing pressure side 156.

[0066] The trunnion 134 includes an inner surface 166 that defines a socket 168. When viewed along a plane extending along the axis 164 of the spar centerline, the socket 168 may include a cross-sectional area. The cross-sectional area of ​​the socket 168 can be of any suitable shape, such as, but not limited to, rectangular, flared, curved, or combinations thereof. The trunnion 134 includes an upper edge 170 opposite the root 140 of the composite airfoil 132. The upper edge 170 is spaced apart from the root 140. The upper edge 170 includes an opening top 172 that opens into the socket 168. The base 160 of the spar 136 extends through the opening top 172 and into the socket 168.

[0067] The transition portion 162 defines the area where the handle 158 and the base 160 interconnect. When viewed along a plane extending along the axis 164 of the spar centerline, the handle 158, base 160, and transition portion 162 are each defined by a corresponding cross-sectional area. The handle 158, transition portion 162, and base 160 may each include a constant or non-constant cross-sectional area. As a non-limiting example, the handle 158 may have a smaller radial width relative to the base 160. The transition portion 162 may be formed as a tapered segment interconnecting the handle 158 and the base 160, such that the transition portion 162 includes a non-constant cross-sectional area extending, either constantly or non-constantly, from the radial width of the handle 158 at the transition portion 162 to the radial width of the base 160 at the transition portion 162.

[0068] The transition portion 162 can extend any suitable axial distance along the spar centerline axis 164. As a non-limiting example, the transition portion 162 can be represented by the planar region where the shank 158 meets the base 160. As a non-limiting example, the shank 158 and the spar 136 can have a constant cross-sectional area. Therefore, the transition portion 162 can be defined as the planar region where the spar 136 exits the airfoil 132. In other words, the shank 158 can be part of the spar 136 that is entirely within the airfoil 132, while the base 160 can be part of the spar 136 that is entirely outside the airfoil 132.

[0069] The wrap 150 is disposed along a corresponding portion of the spar 136 and radially covers that portion. As a non-limiting example, the wrap 150 surrounds or otherwise circumferentially encircles at least a portion of the transition 162. As a non-limiting example, the wrap 150 may completely or partially surround the transition 162. The wrap 150 extends axially along the composite airfoil assembly 130 for any suitable distance. As a non-limiting example, the wrap 150 may extend axially along the base 160 of the spar 136 and terminate axially at the transition 162. Alternatively, the wrap 150 may extend axially beyond the transition 162 and extend axially over at least a portion of the shank 158 or the composite skin 152. As a non-limiting example, the wrap 150 may terminate axially before the upper edge 170. As a non-limiting example, the wrap 150 may terminate axially at the upper edge 170.

[0070] The wrap 150 is attached to the spar 136 by any suitable method. As a non-limiting example, the wrap 150 may be press-fitted onto the spar 136 and maintain frictional contact with the spar 136. As a non-limiting example, the wrap 150 may surround itself and maintain frictional contact with the spar 136. As a non-limiting example, the wrap 150 may be attached to the spar 136 or any other suitable part of the composite airfoil assembly 130 by any suitable method (e.g., but not limited to adhesion, fastening, welding, friction contact, integral forming, bonding, curing, or combinations thereof).

[0071] Figure 4 It is along the axis 164 of the wing spars centerline. Figure 3 When viewed from a plane that extends and intersects the package at 150 degrees. Figure 3A schematic cross-sectional view of the package 150. The package 150 includes a first region 182 and a second region 184, the second region 184 being on either side of the first region 182. The first region 182 defines a central region of the package 150, while the second region 184 defines an edge of the package 150. For illustrative purposes, the transition between the first region 182 and the second region 184 is shown in dashed lines 185.

[0072] Enclosure 150 includes an outer surface 174, an inner surface 176, and a peripheral surface 178. The inner surface 176 faces a corresponding portion of the composite airfoil assembly 130 (e.g., a sparsity 136). The peripheral surface 178 defines the periphery of enclosure 150. Enclosure 150 includes a connecting surface 186 interconnecting the outer surface 174 and the peripheral surface 178. The outer surface 174, inner surface 176, peripheral surface 178, and connecting surface 186 are formed in any suitable manner, such as, but not limited to, linear surfaces, nonlinear surfaces, or combinations thereof. As a non-limiting example, the connecting surface 186 may be circular.

[0073] The connecting surface 186 extends inward from the first region 182 to the peripheral surface 178. In other words, the connecting surface 186, and therefore the second region 184, is defined by the tapered or rounded region of the wrapping 150.

[0074] The package 150 is defined by a series of thicknesses between an inner surface 176 and an outer surface 174 or a connecting surface 186. The package 150 includes a first thickness (T1) and a second thickness (T2). The first thickness (T1) is defined as the thickness of a first region 182. The second thickness (T2) is defined as the thickness of a second region 184. The second thickness (T2) may be located at a corresponding portion of the peripheral surface 178. The first region 182 may include a constant thickness such that the first thickness (T1) defines the maximum thickness of the entire package 150. The first thickness (T1) is greater than the second thickness (T2).

[0075] The first thickness (T1) and the second thickness (T2) are any suitable dimensions. As a non-limiting example, the first thickness (T1) and the second thickness (T2) are greater than or equal to 0.01 inches and less than or equal to 0.2 inches. As a non-limiting example, the first thickness (T1) and the second thickness (T2) are greater than or equal to 0.04 inches and less than or equal to 0.2 inches.

[0076] Figure 5 It is along the axis 164 (relative to the centerline of the wing spars) Figure 3 What is seen from a plane extending circumferentially? Figure 3A schematic diagram of the package 150. For illustrative purposes only, the package 150 has been unfolded and flattened. The view shown is a top-down view of the package 150 along its outer surface 174. A second region 184 extends continuously along the package 150, such that the first region 182 is surrounded or enclosed by the second region 182.

[0077] As shown, the second region 184 extends continuously around the entire first region 182 and defines the entire peripheral surface 178. However, it should be understood that at least a portion of the first region 182 may extend to the peripheral surface 178. As a non-limiting example, the second region 184 may be located on the opposite side of the package 150.

[0078] When viewed from a top-down perspective as shown in the figure, the package 150 may include a rectangular surface area. It should be understood that the package 150 may include a surface area of ​​any suitable shape, such as, but not limited to, a rectangular surface area, a trapezoidal surface area, a triangular surface area, a circular surface area, an oval surface area, a hexagonal surface area, etc.

[0079] Figure 6 yes Figure 2 A bottom-up perspective view of the composite airfoil assembly 130. Airfoil 132 includes a root 140. Airfoil 132 includes a suction side 156 and a pressure side 156. The outer surface 174 of the envelope 150 defines a radially outward portion of the envelope 150. The envelope 150 contacts or is spaced from the root 140 of the airfoil 132.

[0080] The package 150 extends circumferentially around the entire or less than the entire spar centerline axis 164. As a non-limiting example, at least a portion of the peripheral surface 178 of the package 150 may be circumferentially spaced from circumferentially opposite portions of the peripheral surface 178 to define a gap (G) between them. The gap (G) is any suitable size. As a non-limiting example, the gap (G) may be zero, such that the circumferentially opposite ends of the package 150 contact each other.

[0081] The size of the clearance (G) is selected, at least in part, based on the manufacture of the composite airfoil assembly 130. As a non-limiting example, the enclosure 150 may be flattened before being attached to the sparsity 136 (e.g., Figure 5(As shown). The wrap 150 can then be bent or otherwise wrapped around the corresponding portion of the spar 136. Conceivedly, the larger the gap (G), the smaller the distance the wrap 150 needs to be bent. Therefore, providing a larger gap (G) reduces the burden of attaching the wrap 150 to the spar 136. As a non-limiting example, the wrap 150 comprises a metallic material. The wrap 150 can be heated to increase its moldability. The heated wrap 150 can then be press-fitted around the corresponding portion of the composite airfoil assembly 30 and subsequently attached to the composite airfoil assembly 30 by any suitable joining method (e.g., but not limited to welding, adhesion, friction, bonding, fastening, etc.).

[0082] The package 150 can have any suitable construction. As a non-limiting example, the connecting surface 186 can extend approximately less than the entire total peripheral surface 178. As a non-limiting example, the connecting surface 186 or a tapered surface can be positioned on opposite axial sides of the package 150 relative to the spar centerline axis 164, and a first region 182 can extend to the peripheral surface 178 on opposite circumferential ends of the package 150. As a non-limiting example, when the clearance (G) is zero, the connecting surface 186 can be omitted from the opposite circumferential ends of the package 150, such that the opposite circumferential ends are in contact.

[0083] During operation of the compound airfoil assembly 130, the working airflow (Fw) flows from the leading edge 144 to the trailing edge 146 on the compound airfoil 132. As the working airflow (Fw) flows on the compound airfoil 132, the compound airfoil extracts work from the working airflow (Fw). As a non-limiting example, the compound airfoil assembly 130 may be located in fan section 18 ( Figure 1 The composite airfoil 132 can be used to guide the working airflow to the turbine engine 10. Figure 1 In the corresponding part of ), the compound airfoil 132 can be further rotated in the operating rotation direction (Dr). Alternatively, the compound airfoil 132 can be static.

[0084] It is envisioned that during operation of the compound airfoil assembly 130, at least one of the working airflow (Fw), the rotation of the compound airfoil 132 in the operating rotation direction (Dr), or a combination thereof, will transmit or induce forces to the compound airfoil 132. As a non-limiting example, the working airflow (Fw) can transmit forces aligned with the direction of the working airflow (Fw) to the compound airfoil 132. As a non-limiting example, due to the drag of the compound airfoil 132, the rotation of the compound airfoil 132 in the operating rotation direction (Dr) results in a force experienced along the compound airfoil 132 opposite to the operating rotation direction (Dr). The forces experienced along the compound airfoil 132 during operation of the compound airfoil assembly 130 will be referred to hereinafter as operating forces. Operating forces may further include any other suitable forces, such as, but not limited to, external forces applied to the compound airfoil assembly 130.

[0085] The operating force along the composite airfoil 132 is transmitted from the composite airfoil 132 to the sparsity 136. It is envisioned that the sparsity 136 will be at the transition section 162 ( Figure 3 The maximum force is experienced at the transition section 162 along the spars 136. The wrapping 150 is used to reinforce the composite airfoil assembly 130 at the transition section 162 that experiences the highest operating force along the spars 136.

[0086] The material, dimensions, orientation, or combination thereof of the wrapper 150 are used to reinforce the composite airfoil assembly 130 against operating forces. As a non-limiting example, the wrapper 150 may be metallic and therefore more resilient to operating forces compared to the composite ceramic material of the spar 136. It is envisioned that the construction of the wrapper 150 could result in the wrapper 150 being better suited to reinforce the spar 136 against operating forces. As a non-limiting example, forming the wrapper 150 with a tapered section (e.g., a second region 184) helps transfer operating forces from the spar 136 to the wrapper 150. Specifically, compared to a wrapper 150 without a connecting surface 186, the connecting surface 186 creates a smoother transition between the wrapper 150 and the spar 136. This smooth transition between the wrapper 150 and the spar 136 further reduces potential contact edge stresses between the wrapper 150 and the spar 136. The wrapper 150 also provides a load transition from the composite skin 152 to the spar 136. Enclosure 150 helps distribute the load between composite skin 152 and spar 136.

[0087] Figure 7 It is suitable for use as Figure 2 A top-down cross-sectional view of an exemplary airfoil assembly 230 of the compound airfoil assembly 130. The compound airfoil assembly 230 is similar to the compound airfoil assembly 130; therefore, similar portions will be identified by similar numbers increasing to the 230 series. It should be understood that, unless otherwise indicated, the description of the compound airfoil assembly 130 applies to the compound airfoil assembly 230.

[0088] The composite airfoil assembly 230 includes a sparsity 236. The sparsity 236 has a centerline axis 264. The composite airfoil assembly 230 includes an enclosure 250. The enclosure 250 includes an inner surface 276, an outer surface 274, a peripheral surface 278, and a connecting surface 286. The enclosure 250 includes a first region 282 and a second region 284. The transition between the first region 282 and the second region 284 is indicated by a dashed line 285.

[0089] Package 250 and Package 150 ( Figure 3 Similar to the package 250, the package includes a gap (G) formed between circumferentially opposite portions of the peripheral surface 278. However, the package 250 includes multiple bodies. As a non-limiting example, the package 250 includes a first body 290 and a second body 292 circumferentially spaced from the first body 290. Thus, two gaps (G) are provided. Although two bodies are shown, it should be understood that the package 250 includes any number of two or more bodies circumferentially spaced about the spar centerline axis 264. Although described as two completely separate bodies, it should be understood that the first body 290 is connected to the second body 292. As a non-limiting example, the first body 290 and the second body 292 may extend from a common body (not shown) such that the package 250 extends entirely or at least partially about the spar centerline axis 264. The package 250 may be symmetrical or asymmetrical about the spar centerline axis 264.

[0090] Figure 7 The package 250 shown reduces the load on attaching the package 250 to the spar 236. Because the package 250 includes at least two bodies, the total distance that each body of the package 250 must bend around the spar 236 is reduced compared to a package 150 that may include a single body.

[0091] Figure 8 It is suitable for use as Figure 2 A top-down cross-sectional view of an exemplary airfoil assembly 330 of the compound airfoil assembly 130. The compound airfoil assembly 330 is similar to compound airfoil assemblies 130 and 230; therefore, similar portions will be identified by similar numbers increasing to the 330 series. It should be understood that, unless otherwise indicated, the description of compound airfoil assemblies 130 and 230 applies to compound airfoil assembly 330.

[0092] The composite airfoil assembly 330 includes a sparsity 336. The sparsity 336 has a sparsity centerline axis 364. The composite airfoil assembly 330 includes an enclosure 350. The enclosure 350 includes an inner surface 376 and an outer surface 374.

[0093] Package 350 and Package 150 ( Figure 3 ), 250 Figure 7 The similarity is that the enclosure 350 at least partially surrounds the centerline axis 364 of the spar. However, the enclosure 350 is formed as a continuous body extending circumferentially around the entire centerline axis 364 of the spar.

[0094] The enclosure 350 may include a composite material. The enclosure 350 may be co-cured with or otherwise bonded to at least the spar 336. In this way, the enclosure 350 and the spar 336 can form a single body.

[0095] Compared to wrappers formed of metallic materials, when wrappers 350 are formed of composite materials, wrappers 350 can further allow for additional customization of the material properties of wrappers 350. Composite materials can include a set of composite layups. Each composite layup can include at least one fiber bundle. As used herein, a fiber bundle refers to a bundle of continuous filaments or fibers, wherein each fiber in the bundle has its own central axis and extends along its own central axis. When a composite layup includes more than one fiber bundle, the fiber bundles of the composite layup can be interlaced (e.g., braided or woven) together and subsequently bonded together to form a composite layup with at least a bidirectional fiber orientation. Composite layups with a single fiber bundle have a unidirectional fiber orientation. Variations in the number of fiber bundles, and therefore variations in fiber orientation, are used to customize the material properties of the composite layup. As a non-limiting example, a composite layup with a bidirectional fiber orientation can have greater resilience to shear stress compared to a composite layup with a unidirectional fiber orientation.

[0096] The wrapping 350 can be formed from any suitable number of composite plies having any suitable fiber orientation. The number of composite plies or the fiber orientation of the composite plies of the wrapping 350 can be selected based on the anticipated forces that the composite airfoil assembly 330, in which the wrapping 350 is disposed, will experience. In other words, the wrapping 350 can be configured to best withstand the anticipated forces that the wrapping 350 will experience.

[0097] Figure 9 It is suitable for use as Figure 2 A schematic cross-sectional view of an exemplary airfoil assembly 430 of the composite airfoil assembly 130. The composite airfoil assembly 430 is similar to composite airfoil assemblies 130, 230, and 330; therefore, similar portions will be identified by similar numbers increasing to the 430 series. It should be understood that, unless otherwise stated, the description of composite airfoil assemblies 130, 230, and 330 applies to composite airfoil assembly 430.

[0098] The composite airfoil assembly 430 includes a sparsity 436, a trunnion 434, and a composite airfoil 432. The composite airfoil 432 includes a composite skin 452. The composite airfoil 432 includes a suction side 454 and a pressure side 456. The sparsity 436 includes a shank 458 extending into a corresponding portion of the composite airfoil 432 and includes a base 460. The base 460 and the shank 458 are interconnected by a transition 462. The sparsity 436 has a sparsity centerline axis 464. The trunnion 434 includes an upper edge 470 having an open top 472 and an inner surface 466 defining a recess 468. The recess 468 extends upward toward the open top 472. The composite airfoil assembly 430 includes a cover 450. The cover 450 is formed as any suitable cover 150 described herein. Figure 3 ), 250 Figure 7 ), 350 Figure 8 ).

[0099] Composite airfoil assembly 430 and composite airfoil assembly 130 ( Figure 2 ), 230 Figure 7 ), 330 Figure 8 Similar to the previous type, the wrapping 450 surrounds at least the transition 462. However, the composite airfoil assembly 430 includes a composite skin 452 extending along the transition 462. The composite skin 452 may terminate along the transition 462 or extend axially beyond the transition 462 and extend over a corresponding portion of the base 460. At least a portion of the wrapping 450 is radially disposed over a corresponding portion of the composite skin 452 such that at least a portion of the composite skin 454 is radially sandwiched between the spar 436 and the wrapping 450. As a non-limiting example, the wrapping 450 may extend over the entire composite skin 452, extending through the transition and toward the trunnion 434. The wrapping 450 may extend axially past the location where the composite skin 452 terminates and axially toward the trunnion 434, such that a first portion of the wrapping 450 directly contacts and covers the composite skin 452, and a second portion of the wrapping 450 directly contacts and covers the spar 436. Alternatively, the wrapping 450 may terminate axially at the location where the composite skin 452 terminates axially.

[0100] Providing an envelope 450 on at least a portion of the composite skin 452 allows for a stronger bond between the composite airfoil 432 and the spars 436. The envelope 450 may surround a portion of the composite skin 452, the spars 436, or a combination thereof, and subsequently be coupled to the composite skin 454, the spars 436, or a combination thereof. As a non-limiting example, the envelope 450 may be bonded to or co-cured with the composite skin 452 and the spars 436, such that the envelope 450, the composite skin 452, and the spars 436 form a single body. As a non-limiting example, the envelope 450 may surround the composite skin 452, the spars 436, or a combination thereof, such that the composite skin 452 remains in frictional contact with the spars 436 due to compression of the envelope 450 surrounding the composite skin 452.

[0101] Figure 10 It is suitable for use as Figure 2 A schematic cross-sectional view of an exemplary airfoil assembly 530 of the composite airfoil assembly 130. The composite airfoil assembly 530 is similar to composite airfoil assemblies 130, 230, 330, and 430; therefore, similar portions will be identified by similar numbers increasing to the 530 series. It should be understood that, unless otherwise indicated, the description of composite airfoil assemblies 130, 230, 330, and 430 applies to composite airfoil assembly 530.

[0102] The composite airfoil assembly 530 includes a sparsity 536, a trunnion 534, and a composite airfoil 532. The composite airfoil 532 includes a composite skin 552. The composite airfoil 532 includes a suction side 554 and a pressure side 556. The sparsity 536 includes a shank 558 extending into a corresponding portion of the composite airfoil 532 and includes a base 560. The base 560 and the shank 558 are interconnected via a transition 562. The sparsity 536 has a sparsity centerline axis 564. The trunnion 534 includes an upper edge 570 having an open top 572 and an inner surface 566 defining a recess 568. The recess 568 extends upward toward the open top 572. The composite airfoil assembly 530 includes a cover 550. The cover 550 is formed as any suitable cover 150 described herein. Figure 3 ), 250 Figure 7 ), 350 Figure 8 ), 450 Figure 9 ).

[0103] Composite airfoil assembly 530 and composite airfoil assembly 130 ( Figure 2 ), 230 Figure 7 ), 330 Figure 8 ), 430 Figure 9 The similarity to package 550 is that package 550 surrounds at least transition portion 562. Similar to package 450 ( Figure 9Similarly, at least a portion of the wrapper 550 extends over the composite skin 552, such that at least a portion of the composite skin 552 is radially disposed between a corresponding portion of the wrapper 550 and the spar 536. However, the wrapper 550 extends axially beyond the transition portion 562 and extends over a corresponding portion of the handle 558.

[0104] The composite airfoil assembly 530 also includes a second enclosure 592. The second enclosure 592 may be radially disposed on at least a portion of the enclosure 550. The second enclosure 592 may extend axially beyond the transition portion 562 and beyond the end of the enclosure 550. Alternatively, the second enclosure 592 may terminate axially along the transition portion 562, terminate axially at the end of the enclosure 550, or a combination thereof.

[0105] Package 550 and package 592 may include the same or different materials or constructions. As a non-limiting example, with package 150 ( Figure 2 Similarly, package 550 may include gaps (not shown) formed between circumferentially adjacent portions of package 550. As a non-limiting example, package 550 may be formed to be adjacent to package 150. Figure 2 Similar to package 350, and the second package 592 can be formed as if it were package 350. Figure 8 Similar to the second package 592, the package 550 may include a gap, and the second package 592 may extend continuously about the spar centerline axis 564, including extending circumferentially through the gap. Thus, at least a portion of the second package 592 may contact or otherwise directly cover a corresponding portion of the spar 536 (e.g., through the gap). As a non-limiting example, the package 550 or the second package 592 may include a metallic material, while the other of the package 550 or the second package 592 may include a composite material. As a non-limiting example, the package 550 may extend circumferentially about a distance less than the entire spar centerline axis 564, while the second package 592 may extend circumferentially about a distance greater than or equal to the entire spar centerline axis 564.

[0106] Benefits associated with this disclosure include greater resilience to operating forces compared to conventional variable-pitch airfoil assemblies. For example, a conventional variable-pitch airfoil assembly may include a sparsity extending from the compound airfoil and into the trunnion. However, the sparsity will experience relatively large forces at the location where the sparsity transitions from the shank to the base or at the location where the sparsity exits the compound airfoil. These relatively large forces can cause damage to the sparsity itself. However, the variable-pitch airfoil assembly as described herein includes at least one of a wrapping or a second wrapping to reinforce the area of ​​the sparsity that will experience these relatively large forces. This, in turn, limits or otherwise minimizes damage associated with operating forces experienced along the variable-pitch airfoil assembly compared to conventional variable-pitch airfoil assemblies.

[0107] Within the scope not described herein, various features and structures of the various embodiments may be combined or substituted for each other as needed. The fact that a feature is not shown in all embodiments is not to be construed as meaning it cannot be shown in this way, but is done for the sake of brevity. Therefore, various features of different embodiments may be mixed and matched as needed to form new embodiments, whether or not the new embodiments are explicitly described. All combinations or permutations of the features described herein are covered by this disclosure.

[0108] This written description uses examples to illustrate aspects of the disclosure described herein, including best practices, and also enables any person skilled in the art to practice aspects of the disclosure, including making and using any apparatus or system and performing any combination of methods. The patentable scope of aspects of this disclosure 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 fall within the scope of the claims if they have 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.

[0109] Further details are provided by the following topics:

[0110] A composite airfoil assembly includes: a composite airfoil having an outer wall extending between a root and a tip and defining an interior, the composite airfoil having a composite skin forming at least a portion of the outer wall; a spar having a spar centerline axis, a shank extending into at least a portion of the interior, a base located outside the root of the composite airfoil, and a transition portion interconnecting the shank and the base; and an enclosure at least partially surrounding the transition portion.

[0111] The composite airfoil assembly according to any of the foregoing clauses, wherein the enclosure comprises a metallic material.

[0112] According to any of the foregoing clauses, the composite airfoil assembly wherein the enclosure completely circumferentially surrounds the transition portion.

[0113] The composite airfoil assembly according to any of the foregoing clauses, wherein the package comprises a composite material.

[0114] According to any of the foregoing clauses, the composite airfoil assembly, wherein the composite skin extends axially over the transition relative to the centerline axis of the spar.

[0115] According to any of the foregoing clauses, the composite airfoil assembly, wherein the composite skin extends radially between the wrapper and the transition portion.

[0116] According to any of the foregoing clauses, the composite airfoil assembly wherein the wrapping extends axially beyond the transition portion and extends over at least a portion of the composite skin.

[0117] According to any of the foregoing clauses, the composite airfoil assembly, wherein the enclosure is a first enclosure, and the composite airfoil assembly further includes a second enclosure that at least partially surrounds the first enclosure.

[0118] According to any of the foregoing clauses, the composite airfoil assembly, wherein the first enclosure comprises a metallic material and the second enclosure comprises a composite material.

[0119] According to any of the preceding clauses, in the composite airfoil assembly, the first enclosure extends circumferentially less than the entire centerline axis of the spar, and the second enclosure extends circumferentially greater than or equal to the entire centerline axis of the spar.

[0120] The composite airfoil assembly according to any of the foregoing clauses, wherein the package comprises at least two bodies circumferentially spaced apart from each other.

[0121] According to any of the foregoing clauses, the composite airfoil assembly includes a circumferential distal end, wherein a gap is formed between the circumferential distal ends.

[0122] The composite airfoil assembly according to any of the foregoing clauses, wherein the gap is greater than zero.

[0123] According to any of the preceding clauses, the composite airfoil assembly, when viewed along a horizontal plane perpendicular to the centerline axis of the spar, includes a cross-sectional area comprising a first region having a first thickness and a second region having a second thickness less than the first thickness.

[0124] According to any of the foregoing clauses, the composite airfoil assembly wherein the second thickness decreases linearly or non-linearly from the first region to the thickness of the wrapping.

[0125] According to any of the foregoing clauses, the composite airfoil assembly wherein the first thickness is constant.

[0126] A turbine engine including a composite airfoil assembly according to any of the preceding clauses, the turbine engine further including a fan section, a compressor section, a combustion section and a turbine section arranged in a series flow configuration and defining a stator section and a rotor section, the rotor section rotating about an engine centerline, the composite airfoil being disposed within the rotor section.

[0127] A turbine engine comprising a composite airfoil assembly according to any of the foregoing clauses, wherein the turbine engine is a non-pipeline turbine engine and the composite airfoil is an external fan blade.

[0128] The turbine engine according to any of the foregoing clauses, wherein the package comprises a metallic material.

[0129] According to any of the foregoing clauses, the turbine engine wherein the enclosure completely circumferentially surrounds the transition portion.

[0130] The turbine engine according to any of the foregoing clauses, wherein the package comprises a composite material.

[0131] According to any of the foregoing clauses, the composite skin extends axially over the transition relative to the centerline axis of the spar.

[0132] The turbine engine according to any of the foregoing clauses, wherein the composite skin extends radially between the wrapping and the transition portion.

[0133] The turbine engine according to any of the foregoing clauses, wherein the package extends axially beyond the transition portion and extends over at least a portion of the composite skin.

[0134] According to any of the foregoing clauses, the turbine engine, wherein the enclosure is a first enclosure, and the composite airfoil assembly further includes a second enclosure that at least partially surrounds the first enclosure.

[0135] The turbine engine according to any of the foregoing clauses, wherein the first package comprises a metallic material and the second package comprises a composite material.

[0136] According to any of the preceding clauses, the turbine engine wherein the first enclosure extends circumferentially less than the entire centerline axis of the spar, and the second enclosure extends circumferentially greater than or equal to the entire centerline axis of the spar.

[0137] The turbine engine according to any of the foregoing clauses, wherein the package comprises at least two bodies circumferentially spaced apart from each other.

[0138] The turbine engine according to any of the foregoing clauses, wherein the package includes a circumferential distal end, wherein a gap is formed between the circumferential distal ends.

[0139] The turbine engine according to any of the foregoing clauses, wherein the clearance is greater than zero.

[0140] According to any of the preceding clauses, the turbine engine, when viewed along a horizontal plane perpendicular to the centerline axis of the spar, comprises a cross-sectional area including a first region having a first thickness and a second region having a second thickness less than the first thickness.

[0141] According to any of the foregoing clauses, the second thickness decreases linearly or non-linearly from the first region to the thickness of the package.

[0142] The turbine engine according to any of the foregoing clauses, wherein the first thickness is constant.

[0143] A composite variable pitch airfoil assembly includes: a composite airfoil having an outer wall extending between a root and a tip and defining an interior, the composite airfoil having a composite skin forming at least a portion of the outer wall; a sparsity having a sparsity centerline axis, a shank extending into at least a portion of the interior, a base located outside the root of the composite airfoil, and a transition portion interconnecting the shank and the base; a trunnion having an upper edge and a wall, the upper edge having an open top, the wall having a set of internal surfaces defining a recess extending from the open top, wherein at least a portion of the base extends through the open top and into the recess; and an enclosure at least partially surrounding the transition portion.

[0144] According to any of the foregoing clauses, the composite variable pitch airfoil assembly wherein the package terminates axially prior to the trunnion relative to the centerline axis of the spar.

[0145] The composite variable pitch airfoil assembly according to any of the foregoing clauses, wherein the enclosure comprises a metallic material.

[0146] According to any of the foregoing clauses, the composite variable pitch airfoil assembly, wherein the enclosure completely circumferentially surrounds the transition portion.

[0147] The composite variable pitch airfoil assembly according to any of the foregoing clauses, wherein the package comprises a composite material.

[0148] According to any of the foregoing clauses, the composite variable pitch airfoil assembly, wherein the composite skin extends axially over the transition relative to the centerline axis of the spar.

[0149] The composite variable pitch airfoil assembly according to any of the foregoing clauses, wherein the composite skin extends radially between the wrapper and the transition.

[0150] According to any of the foregoing clauses, the composite variable pitch airfoil assembly, wherein the wrapping extends axially beyond the transition portion and extends over at least a portion of the composite skin.

[0151] According to any of the foregoing clauses, the composite variable pitch airfoil assembly, wherein the enclosure is a first enclosure, and the composite airfoil assembly further includes a second enclosure that at least partially surrounds the first enclosure.

[0152] The composite variable pitch airfoil assembly according to any of the foregoing clauses, wherein the first enclosure comprises a metallic material and the second enclosure comprises a composite material.

[0153] According to any of the foregoing clauses, the composite variable pitch airfoil assembly wherein the first enclosure extends circumferentially less than the entire spar centerline axis, and the second enclosure extends circumferentially greater than or equal to the entire spar centerline axis.

[0154] The composite variable pitch airfoil assembly according to any of the foregoing clauses, wherein the package comprises at least two bodies circumferentially spaced apart from each other.

[0155] According to any of the foregoing clauses, the composite variable pitch airfoil assembly includes a circumferential distal end, wherein a gap is formed between the circumferential distal ends.

[0156] The composite variable pitch airfoil assembly according to any of the foregoing clauses, wherein the gap is greater than zero.

[0157] According to any of the preceding clauses, the composite variable pitch airfoil assembly, when viewed along a horizontal plane perpendicular to the centerline axis of the spar, includes a cross-sectional area comprising a first region having a first thickness and a second region having a second thickness less than the first thickness.

[0158] According to any of the foregoing clauses, the composite variable pitch airfoil assembly wherein the second thickness decreases linearly or non-linearly from the first region to the thickness of the wrapping.

[0159] The composite variable pitch airfoil assembly according to any of the foregoing clauses, wherein the first thickness is constant.

Claims

1. A composite airfoil component assembly, characterized in that, include: A composite airfoil having an outer wall extending between a root and a tip and defining an interior, the composite airfoil having a composite skin forming at least a portion of the outer wall; A spar having a spar centerline axis, a shank extending into at least a portion of the interior, a base located outside the root of the composite airfoil, and a transition portion connecting the shank and the base. as well as An enclosure that at least partially surrounds the transition section and contacts corresponding portions of the spar and the composite airfoil, wherein the enclosure is used to reinforce the composite airfoil assembly at the transition section experiencing the highest operating force along the spar.

2. The composite airfoil assembly according to claim 1, characterized in that, in, The package contains metallic materials.

3. The composite airfoil assembly according to claim 1, characterized in that, in, The package completely surrounds the transition section circumferentially.

4. The composite airfoil assembly according to claim 1, characterized in that, in, The package includes a composite material.

5. The composite airfoil assembly according to claim 1, characterized in that, in, The composite skin extends axially above the transition section relative to the centerline axis of the wing spars.

6. The composite airfoil assembly according to claim 1, characterized in that, in, The package is a first package, and the composite airfoil assembly further includes a second package that at least partially surrounds the first package.

7. The composite airfoil assembly according to claim 6, characterized in that, in, The first package extends circumferentially less than the entire centerline axis of the spar, and the second package extends circumferentially greater than or equal to the entire centerline axis of the spar.

8. The composite airfoil assembly according to claim 1, characterized in that, in, When viewed along a horizontal plane perpendicular to the centerline axis of the spar, the package includes a cross-sectional area comprising a first region having a first thickness and a second region having a second thickness less than the first thickness.

9. The composite airfoil assembly according to claim 8, characterized in that, in, The second thickness decreases linearly or non-linearly from the first region to the minimum thickness of the package.

10. The composite airfoil assembly according to claim 8, characterized in that, in, The first thickness is constant.

11. The composite airfoil assembly according to claim 1, characterized in that, in, The composite airfoil assembly is a composite variable pitch airfoil assembly.

12. The composite airfoil assembly according to claim 11, characterized in that, in, The composite airfoil assembly is located within a turbine engine having a fan section with multiple fan blades, wherein the composite airfoil assembly is disposed within the multiple fan blades.

13. The composite airfoil assembly according to claim 1, characterized in that, in, The package includes a first region and a second region extending from the first region to a peripheral surface of the package, the second region being defined by a portion of the package's thickness decreasing between the first region and the peripheral surface.

14. A turbine engine comprising a composite airfoil assembly according to claim 1, characterized in that, The turbofan engine further includes a fan section, a compressor section, a combustion section and a turbine section arranged in a series flow configuration, and defines a stator section and a rotor section, the rotor section rotating about the engine centerline, the composite airfoil being disposed within the rotor section.

15. A turbine engine comprising a composite airfoil assembly according to claim 1, characterized in that, The turbine engine is a non-pipeline turbine engine, and the composite airfoil is an external fan blade.

16. A composite airfoil component assembly, characterized in that, include: A composite airfoil having an outer wall extending between a root and a tip and defining an interior, the composite airfoil having a composite skin forming at least a portion of the outer wall; A spar having a spar centerline axis, a shank extending into at least a portion of the interior, a base located outside the root of the composite airfoil, and a transition portion connecting the shank and the base. as well as An enclosure that at least partially surrounds the transition section, wherein the enclosure is used to reinforce the composite airfoil assembly at the transition section experiencing the highest operating force along the spars; The composite skin extends axially above the transition portion relative to the centerline axis of the wing spar, and the composite skin is located radially between the wrapper and the transition portion relative to the centerline axis of the wing spar.

17. A composite airfoil component assembly, characterized in that, include: A composite airfoil having an outer wall extending between a root and a tip and defining an interior, the composite airfoil having a composite skin forming at least a portion of the outer wall; A spar having a spar centerline axis, a shank extending into at least a portion of the interior, a base located outside the root of the composite airfoil, and a transition portion connecting the shank and the base. as well as An enclosure that at least partially surrounds the transition section, wherein the enclosure is used to reinforce the composite airfoil assembly at the transition section experiencing the highest operating force along the spars; The package extends axially beyond the transition portion and extends over at least a portion of the composite skin.

18. A composite airfoil component assembly, characterized in that, include: A composite airfoil having an outer wall extending between a root and a tip and defining an interior, the composite airfoil having a composite skin forming at least a portion of the outer wall; A spar having a spar centerline axis, a shank extending into at least a portion of the interior, a base located outside the root of the composite airfoil, and a transition portion connecting the shank and the base. A first package, the first package at least partially surrounding the transition portion, the first package comprising a metallic material; as well as A second package, which at least partially surrounds the first package, the second package comprising a composite material; The first and second wrappings are used to reinforce the composite airfoil at the transition section where the highest operating force along the spar is experienced.

19. A composite airfoil component assembly, characterized in that, include: A composite airfoil having an outer wall extending between a root and a tip and defining an interior, the composite airfoil having a composite skin forming at least a portion of the outer wall; A spar having a spar centerline axis, a shank extending into at least a portion of the interior, a base located outside the root of the composite airfoil, and a transition portion connecting the shank and the base. as well as An enclosure that at least partially surrounds the transition section, wherein the enclosure is used to reinforce the composite airfoil assembly at the transition section experiencing the highest operating force along the spars; The package includes a circumferential distal end, and a gap is formed between the circumferential distal ends.

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