Airfoil assembly

Abstract

An airfoil assembly has an airfoil portion and a spar. The airfoil portion has an outer wall. The outer wall extends in a spanwise direction between a root and a tip, and in a chordwise direction between a leading edge and a trailing edge. The outer wall defines an interior. The spar has a spar body. A spar is coupled to the airfoil portion. The spar extends into the interior.

Description

Technical Field

[0001] This disclosure generally relates to airfoil assemblies, and more specifically, to airfoil assemblies comprising airfoil sections and spars. Background Technology

[0002] 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.

[0003] 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

[0004] 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:

[0005] Figure 1 This is a schematic cross-sectional view of a turbine engine, which is an open rotor turbine engine according to an exemplary embodiment of the present disclosure.

[0006] Figure 2 Is it suitable for Figure 1 A schematic diagram of an airfoil assembly used in a turbine engine, which includes an airfoil section and a spars.

[0007] Figure 3 From Figure 2 The schematic cross-sectional view of the airfoil assembly seen in section line III-III further illustrates the airfoil having a spar body and a set of pockets disposed within the spar body.

[0008] Figure 4 From Figure 3 The schematic cross-sectional view of the wing spars seen from section line IV-IV further illustrates two through pockets in this group of pockets.

[0009] Figure 5 From Figure 3 The schematic cross-sectional view of the wing beam seen from the section line VV further shows two parts of the sling through the sling.

[0010] Figure 6 From Figure 3 The schematic cross-sectional view of the wing beam seen from section line VI-VI further shows the through-hole and partial through-hole sections in this group of pockets.

[0011] Figure 7 From Figure 3 The schematic cross-sectional view of the wing beam seen through section line VII-VII further illustrates the inner pocket within this group of pockets. Detailed Implementation

[0012] The aspects disclosed herein relate to airfoil assemblies for turbine engines. The airfoil assembly includes an airfoil portion and a sparsity. The sparsity includes a sparsity body defining a peripheral surface of the sparsity. The sparsity includes a set of pockets disposed within the sparsity body. Each pocket in the set of pockets forms a cavity disposed within the sparsity body.

[0013] This set of pockets is used to reduce the overall weight of the spar without sacrificing the structural integrity of the spar. For illustrative purposes, this disclosure will be described with respect to airfoil assemblies of turbine engines, particularly turbine engine fan blades. However, it will be understood that the aspects of this disclosure described herein are not limited thereto and can have general applicability in other engines or other parts of turbine engines. For example, this disclosure can be applied to airfoil assemblies in other engines or vehicles. Furthermore, this disclosure can provide benefits in industrial, commercial, and residential applications.

[0014] 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.

[0015] 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.

[0016] 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.

[0017] 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.

[0018] 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.

[0019] 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.

[0020] One or more adhesive layers may be used to form or bond composite components. The adhesive may include resins and phenolic resins, where the adhesive may require curing at elevated temperatures or other hardening techniques.

[0021] 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.

[0022] 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.

[0023] 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.

[0024] 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.

[0025] 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.

[0026] 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.

[0027] 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.

[0028] 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.

[0029] 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.

[0030] 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.

[0031] 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).

[0032] 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.

[0033] 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.

[0034] Figure 1This is a schematic cross-sectional view of a turbine engine 10, particularly an open rotor or non-ducted turbine engine for an aircraft, but this disclosure is not limited thereto. The 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 turbine engine 10 includes a set of circumferentially spaced blades or propellers in a downstream series flow arrangement 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 compressor section 22, combustion section 28, and turbine section 32 are arranged in a series flow arrangement. The 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.

[0035] The outer surface of the turbine engine 10, defined by the casing or nacelle 40, extends from the front end 14 of the turbine engine 10 toward the rear end 16 of the 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 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 fan wheel 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 fan wheel blades 82 extend radially outward from corresponding portions of the nacelle 40. Thus, the set of fan blades 42 and the set of fan wheel blades 82 may be defined as an outer set of fan blades and an outer set of fan wheel blades 82, respectively. The 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 fan blades 82. As a non-limiting example, the turbine engine 10 may include multiple sets of fan blades 42 or a set of fan blades 82. Therefore, the turbine engine 10 is further defined as a single-fan turbine engine. The 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.

[0036] 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 turbine engine 10.

[0037] An HP shaft or spool 48, coaxially arranged around the engine centerline 12 of the 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 around the engine centerline 12 of the 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.

[0038] It should be understood that the 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.

[0039] 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 compressor stages 52 and 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.

[0040] 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.

[0041] 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 within this set of turbine stages 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.

[0042] 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.

[0043] The rotating parts of the turbine engine 10 (e.g., compressor blades 56, 58 and turbine blades 68, 70 in 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 turbine engine 10.

[0044] Complementing the rotating parts, the stationary parts of the turbine engine 10 (e.g., the static compressor blades 60, 62 and the static turbine blades 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 turbine engine 10.

[0045] The nacelle 40 is operatively coupled to the 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 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).

[0046] It should be understood that the 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 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 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 the set of fan blades 82, static compressor blades 60, 62, or static turbine blades 72, 74.

[0047] During operation of the turbine engine 10, a free-flowing airflow 80 flows against the front of the 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 the swept area between the outer surface of the nacelle 40 and the tips of the fan blades 42, where this airflow is the working airflow 76. A portion of the working airflow 76 enters the engine core 44 and is used for combustion within the engine core 44.

[0048] 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 fuel in the combustor 30 and ignites, 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 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 turbine engine 10.

[0049] The working airflow 76 and at least some external airflows 78 converge downstream of the exhaust section 38 of the turbine engine 10. Together, the working airflow 76 and the external airflows 78 form the total thrust of the turbine engine 10.

[0050] Imagine a portion of the working airflow 76 is drawn as bleed air 77 (e.g., from compressor section 22). Bleed air 77 provides 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 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 combustion section 28. Other sources of cooling fluid are, but are not limited to, fluids discharged from LP compressor 24 or HP compressor 26.

[0051] Figure 2 Is it suitable for Figure 1A schematic diagram of an airfoil assembly 100 used within a turbine engine 10. The airfoil assembly 100 may be disposed within the rotor or stator portion of the turbine engine 10. The airfoil assembly 100 includes an airfoil portion 102, which is any suitable airfoil of the turbine engine 10. As a non-limiting example, the airfoil portion 102 may be a blade among a plurality of fan blades 42, or a blade from compressor blades 56, 58 or turbine blades 68, 70. As a non-limiting example, the airfoil portion 102 may be a blade among the set of stationary fan blades 82. It is contemplated that the airfoil portion 102 may be a blade, impeller, airfoil, or other component of any turbine engine (such as, but not limited to, a gas turbine engine, a turboprop engine, a turboshaft engine, a ducted turbofan engine, or turbine engine 10 (e.g., a non-ducted turbine engine)). As a non-limiting example, the airfoil assembly 100 may be defined as a set of external fan blades (from... Figure 1 One of a plurality of fan blades 42 extending outward from the nacelle 40, or one of a plurality of stationary fan blades 82 defined as a set of external fan blades (extending outward from the nacelle 40).

[0052] Airfoil portion 102 includes an outer wall 108 defining an interior 118. The outer wall 108 extends between a leading edge 110 and a trailing edge 112 to define a chordal direction (Cd). The outer wall 108 further extends between a root 114 and a tip 116 to define a span direction (Sd). Airfoil portion 102 has a span length (L) measured along the span direction (Sd) from the root 114 at 0% of the span length (L) to the tip 116 at 100% of the span length (L).

[0053] The airfoil assembly 100 includes a trunnion 104 and a sparsity 106. The sparsity 106 extends into the interior 118 and is formed together with (attached to or integrally formed with) the airfoil portion 102. The sparsity 106 extends outward from the root 114. The sparsity 106 can be operatively coupled to the trunnion 104 (e.g., by coupling, adhesion, fastening, or any other suitable coupling method).

[0054] The airfoil assembly 100 may include additional structures surrounding a corresponding portion of the spar 106. As a non-limiting example, the airfoil assembly 100 may include a sleeve 156 disposed along a corresponding portion of the spar 106. The sleeve 156 may extend into the interior 118. The sleeve 156 may extend into the trunnion 104. The sleeve 156 may be coupled to or integrally formed with the trunnion 104. Alternatively, the sleeve 156 may be omitted from the airfoil assembly 100. When the sleeve 156 is included, it serves to stabilize the spar 106 and increase the spar 106's resistance to bending moments.

[0055] The spar 106 includes a distal end 120. The spar 106 includes a portion 107 defined as a corresponding portion of the spar 106 disposed within an interior 118. The portion 107 of the spar 106 extends an internal length (Ls) in the spanwise direction (Sd) between the distal end 120 and the location where the spar 106 meets the root 114. The internal length (Ls) of the spar is greater than or equal to 30% and less than or equal to 90% of the span length (L). It should be understood that the spar 106 includes a total spar length, which is defined as the total length of the spar 106 extending in the spanwise direction (Sd).

[0056] At least a portion of the airfoil assembly 100 comprises a composite material. As a non-limiting example, the airfoil portion 102 and the spar 106 may each comprise a composite material. As a non-limiting example, the outer wall 108, the spar 106, or combinations thereof may comprise at least a PMC portion, a CMC 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 airfoil portion 102 may comprise a composite material, a non-composite metallic material, any other suitable material, or a combination thereof. As a non-limiting example, the trunnion 104 may be any suitable material, such as, but not limited to, a metallic material or a composite material.

[0057] During operation of the airfoil assembly 100, the trunnion 104 can rotate in the direction of rotation (Rd) about the pitch axis (Pax). When the spars 106 connects the trunnion 104 to the airfoil portion 102, the rotation of the trunnion 104 in the direction of rotation (Rd) causes the airfoil portion 102 to rotate about the pitch axis (Pax). This rotation is used to control the pitch of the airfoil assembly 100. Therefore, the airfoil assembly 100 is defined as a variable-pitch airfoil assembly. The pitch of the airfoil assembly 100 can vary based on the operation or anticipated operation of the turbine engine housed within the airfoil assembly 100.

[0058] Figure 3 From Figure 2A schematic cross-sectional view of a portion of the airfoil assembly 100, as seen along section line III-III. The interior 118 of the airfoil portion 102 is shown as containing solid material. However, it will be understood that at least a portion of the interior 118 is not solid. The spar 106 includes a spar body 124 having a spar centerline 122. The spar centerline 122 is equidistant between opposite sides of the spar 106 in the chordal direction (Cd). The spar body 124 includes a set of pockets 128 formed within the spar body 124. The spar body 124 defines a peripheral surface 126, which is the outer surface of the spar 106.

[0059] The set of pockets 128 is disposed along any suitable portion of the spar body 124. As a non-limiting example, the set of pockets 128 is disposed only along the inner portion 107. The set of pockets 128 are axially spaced relative to the spar centerline 122 along the spar 106, or otherwise spaced along the spar 106 in the spanwise direction (Sd). The set of pockets 128 may be radially spaced relative to the spar centerline 122, or otherwise spaced in the chordwise direction (Cd). It should be understood that the set of pockets 128 may be circumferentially spaced from each other relative to the spar centerline 122.

[0060] Each of the set of pockets 128 forms a corresponding cavity 130 disposed within the spar body 124. Each corresponding cavity 130 includes a volume defined as a three-dimensional region occupied by the corresponding cavity 130 within the spar 106. The three-dimensional region of the corresponding cavity 130 can be any suitable three-dimensional shape, such as, but not limited to, an oval, rectangular prism, pyramid, sphere, etc. As used herein, "cavity" or its iteration refers to a cut or hollow portion formed within the spar 106. Each cavity defined by the set of pockets 128 within the spar body 124 is also defined as a region within the spar body 124 in which the material of the spar body 124 forms the periphery of each of the pockets 128 and the walls between adjacent pockets in the set of pockets 128.

[0061] The group of pockets 128 includes any number of one or more pockets. As a non-limiting example, the group of pockets 128 includes a first pocket 134, a second pocket 136, a third pocket 138, a fourth pocket 140, a fifth pocket 142, a sixth pocket 144, a seventh pocket 146, an eighth pocket 148, a ninth pocket 150, a tenth pocket 152, and a final pocket 154 (shown as an eleventh pocket). The first pocket 134 is defined as the pocket in the group of pockets 128 that is closest to the root 114 in the spanwise direction (Sd). The final pocket 154 is defined as the pocket in the group of pockets 128 that is closest to the distal end 120 in the spanwise direction (Sd). It will be understood that the group of pockets 128 may include any number of pockets greater than or equal to one and less than or equal to 50.

[0062] The set of pockets 128 extends along the spar 106 in the spanwise direction (Sd) between the first pocket 134 and the last pocket 154 by a pocket extension length (Lps). The pocket extension length (Lps) is defined as the total axial distance occupied by the set of pockets 128 relative to the spar centerline 122 along the spar 106. The pocket extension length (Lps) is less than or equal to the spar inner length (Ls). Figure 2 As a non-limiting example, the pocket extension length (Lps) is greater than or equal to 0.1% and less than or equal to 100% of the spar's internal length (Ls). As a non-limiting example, the pocket extension length (Lps) is greater than or equal to 1% and less than or equal to 10% of the spar's internal length (Ls).

[0063] It is conceivable that the group of pockets 128 may include a single continuous pocket. In other words, the group of pockets 128 may include a single continuous pocket as the only pocket disposed within the interior 118. The single continuous pocket in the group of pockets 128 may extend any suitable length within the spar 106. As a non-limiting example, the spar 106 may include a single continuous pocket having a pocket extension length (Lps) greater than or equal to 0.1% and less than or equal to 100% of the spar's interior length (Ls). As a non-limiting example, the spar 106 may include a single continuous pocket having a pocket extension length (Lps) greater than or equal to 1% and less than or equal to 10% of the spar's interior length (Ls). The spar 106 may include multiple pockets, each having a pocket extension length (Lps) between 1% and 10% of the spar's interior length (Ls).

[0064] The spar 106, particularly the inner portion 107 of the spar 106, extends chordally by a length (Cds) in the chordal direction (Cd). The shape of the spar 106 can be determined by... Figure 2 The equation is used to quantify the internal length (Ls) of the spar and the chord extension length (Cds). Specifically, the following equation applies, where “V” is the rectangular volume of the internal portion 107 of the spar 106.

[0065] V = (Cds x Ls) 3

[0066] The set of pockets 128 is located within a rectangular volume (V). It has been found that adding the set of pockets 128 to the rectangular volume (V) (e.g., the inner portion 107) can reduce the overall weight of the spar 106 without sacrificing its overall stiffness. In other words, it has been found that providing the set of pockets 128 within the rectangular volume (V) can reduce the weight of the spar 106 without sacrificing its structural integrity.

[0067] At least one of the pockets 128 may be located in the area of ​​the spar 106 surrounded by the sleeve 156. Alternatively, the pockets 128 may begin after the sleeve 156 terminates in the spanwise (Sd) direction within the interior 118.

[0068] In the illustrated example, at least two pockets in the set of pockets 128 are identical. However, it will be understood that this is not necessary. Furthermore, in the illustrated example, at least two pockets in the set of pockets 128 include different constructions. However, it will be understood that this is not necessary. As a non-limiting example, the corresponding cavity 130 formed by the first pocket 134 may have a larger volume than the corresponding cavity 130 of the second pocket 136. The set of pockets 128 may include at least two pockets having corresponding volumes defined by different shapes. As a non-limiting example, the eighth pocket 148 is formed as a rectangular prism, while, for example, the first pocket 134 is formed as an oval. It is conceivable that the shape of each pocket in the set of pockets 128 may be selected based on the anticipated forces that can be applied to the spar 106 during operation of the airfoil assembly 100. As a non-limiting example, it has been found that utilizing an oval or ovate shape helps to distribute forces evenly along the pocket. As a non-limiting example, using a triangle shape and orienting the vertices of the triangle to align with the desired force (inline with) can help concentrate the force along the pocket and distribute the force to the other two vertices.

[0069] The volume of each corresponding cavity 130 in the group of pockets 128 can increase continuously in the spanwise direction (Sd) from the first pocket 134 to the last pocket 154. In other words, the volume of the corresponding cavity 130 of the first pocket 134 is larger than the volume of the corresponding cavity 130 of the second pocket 136, the volume of the corresponding cavity 130 of the second pocket 136 is larger than the volume of the corresponding cavity 130 of the third pocket 138, and so on, until the last pocket 154.

[0070] The set of pockets 128 is defined by a pocket density. Pocket density refers to the relationship between the spar body 124 of the spar 106 and the set of pockets 128. The pocket density can vary axially along the spar centerline 122. As a non-limiting example, the pocket density near the root 114 can be greater than the pocket density near the distal end 120. The pocket density can decrease from the region of the spar 106 near the root 114 to the distal end 120. In other words, the overall volume of the spar 106 occupied by the set of pockets 128 decreases from the location where the set of pockets 128 begins (e.g., near the root 114) to the region where the set of pockets 128 ends (e.g., near the distal end 120). It is envisioned that during operation, stress will be experienced along the spar 106 due to the operating forces (described further in detail below) associated with the operation of the airfoil assembly. The density of the set of pockets 128 varies based on the magnitude of the expected stress at local locations along the spar 106. As a non-limiting example, reducing the density of the set of pockets 128 in the local region increases the total area of ​​the spar 106 in the local region occupied by the solid material of the spar 106. Increasing the solid material of the spar 106 thereby reduces the overall stress in the local region.

[0071] As a further non-limiting example, at least two pockets in the group of pockets 128 may include different orientations. As a further non-limiting example, the seventh pocket 146 may have a different orientation relative to another pocket in the group of pockets 128 at an angle or otherwise, as shown. It will be understood that the orientation of each pocket in the group of pockets 128 can be varied to maximize the total number of pockets in a local area. In other words, the orientation of each pocket in the group of pockets 128 can be varied to increase or decrease the local density of the group of pockets 128, thereby achieving a desired density at different locations on the spar. Furthermore, changing the orientation can be used to better accommodate anticipated forces along the spar 106. Variations in orientation can allow forces within the spar 106 to be distributed in a desired direction within the spar 106.

[0072] As a further non-limiting example, at least one of the pockets in the group 128 may include a filling material 132 disposed within a corresponding cavity 130. Any number of pockets in the group 128 may include filling material 132. As a non-limiting example, the eighth pocket 148, the ninth pocket 150, the tenth pocket 152, and the last pocket 154 may include filling material 132, while the first pockets 134 to the seventh pockets 146 may be formed without filling material 132. When no filling material 132 is formed, the pockets in the group 128 include corresponding cavities 130 filled with gas (e.g., air) or otherwise formed into a vacuum. The corresponding cavities 130 of at least two pockets in the group 128 may include the same filling material 132. The corresponding cavities 130 of at least two pockets in the group 128 may include different filling materials 132. It is contemplated that the filling material 132 may be used for manufacturing purposes. For example, during the manufacturing process of the spar 106, a filler material 132 may be applied to allow the composite resin material of the spar body 124 to form around the corresponding pockets in the set of pockets 128 that include the filler material 132.

[0073] The filler material 132 is any suitable material disposed within the respective cavity 130 that helps reduce the weight of the airfoil assembly 100, as will be described in further detail below. For example, when the filler material 132 is a foam filler material, the weight of the composite spar body 124 can be reduced. The filler material 132 can be a single material. The filler material 132 can be a combination of materials. The filler material 132 can occupy the entire volume of the respective cavity 130 or less than the entire volume of the respective cavity 130. As a non-limiting example, the filler material 132 can occupy less than the entire volume of the respective cavity 130, such that gas is supplied or a vacuum is formed in the remaining portion of the volume. The filler material 132 can vary between the pockets in the set of pockets 128. As a non-limiting example, at least two pockets in the set of pockets 128 may include (varied) filler materials 132 that are different from each other.

[0074] The set of pockets 128 can be formed within the spar body 124 in any suitable manner. As a non-limiting example, the shape of the spar body 124 can be cast, 3D printed, or otherwise solidified to include the set of pockets 128, such that the set of pockets 128 is integrally formed with the spar 106. As a non-limiting example, the spar 106 can be a composite preform composed of layers of stacked composite plies. The composite preform can include areas corresponding to the set of pockets 128 that are not composed of stacked composite plies. In some embodiments, two or more pockets 128 are separated by a composite material. In some embodiments, one or more pockets 128 are cavities between layers of stacked composite plies. As a non-limiting example, the spar 106 can be formed as a solid material part, and the set of pockets 128 can then be machined into the solid material of the spar 106.

[0075] The spar 106 may be symmetrical about the spar centerline 122. The spar 106 may also be asymmetrical about the spar centerline 122. As a non-limiting example, the set of pockets 128 may be axially staggered relative to the spar centerline 122, such that the spar 106 is asymmetrical about the spar centerline 122. As a non-limiting example, the set of pockets 128 may be asymmetrically distributed along the axial span of the spar 106 relative to the spar centerline 122.

[0076] The set of pockets 128 is used to reduce the overall weight of the spar 106 relative to a spar formed without the set of pockets. As a non-limiting example, the spar body 124 comprises a single material or a collection of materials. The spar body 124 is defined by a first density. The first density is one of the densities of the material when the spar body 124 comprises a single material or the average density of the collection of materials. The first density of the spar body 124 may be greater than or equal to 0.04 lbs / in. 3 And less than or equal to 0.08 lbs / in 3 Each corresponding cavity 130 includes a second density. The second density is defined as the density of the gas (e.g., air) within the cavity, or the density of the filling material 132 disposed within the cavity. The first density is greater than the second density. Because the first density is greater than the second density, the set of pockets 128 defines a region of the spar 106 with a reduced density or weight relative to the material of the spar body 124. Reducing the weight of the spar 106, in turn, reduces the overall weight of the airfoil assembly 100. As a non-limiting example, the overall weight of the airfoil assembly 100 can be reduced by greater than or equal to 5% and less than or equal to 25% of the weight of the airfoil assembly excluding the spar 106 having the set of pockets 128. The reduction in the overall weight of the airfoil assembly 100 reduces the weight of the turbine engine (e.g., Figure 1 The overall weight of the turbine engine 10) is reduced, which in turn improves the overall efficiency of the turbine engine.

[0077] During operation, the airfoil assembly 100 experiences stresses associated with at least one of the following: rotational movement of the airfoil assembly 100, impact of the working airflow along the outer wall 108 of the airfoil portion 102, external forces (e.g., forces applied to the airfoil portion 102 from outside the turbine engine), or combinations thereof. These stresses may be transmitted to the sparsity 106. The stresses are in the form of at least one of torsional stress, bending stress, or combinations thereof.

[0078] The set of pockets 128 is formed to reduce the overall weight of the spar 106 without sacrificing its structural integrity. Specifically, at least one of the infill material 132, the shape of the three-dimensional region of the set of pockets 128, or a combination thereof, is used to ensure that the structural integrity of the spar 106 is not reduced relative to a spar formed without the set of pockets 128. Regarding the shape of the three-dimensional region, an oval or spherical shape has been found to distribute stress uniformly along the set of pockets 128. In other words, the spherical or oval shape of the set of pockets 128 is used to eliminate point stresses (areas of increased stress) along the set of pockets 128. The set of pockets 128 formed in other shapes (e.g., rectangular prisms) will generate point stresses along the vertices of the shape. Regarding the use of the infill material 132, the infill material 132 is used to absorb and distribute stress along its length.

[0079] If the airfoil assembly 100 or the spar 106 breaks, the size and placement of the set of pockets 128 can be used to provide the desired fracture of the airfoil assembly 100 or the spar 106. For example, if an external force (e.g., a bird strike) is applied to the airfoil assembly 100 causing it to break, the size, location, and density of the set of pockets 128 will affect the location where the fracture will occur. As a non-limiting example, if a force (e.g., an operating force or an external force) is applied to the airfoil assembly 100, the size and placement of the set of pockets 128 are selected to result in fracture at a predetermined location. Positioning the set of pockets 128 to determine the location where fracture or breakage may occur allows for selective reinforcement of the areas where fracture or breakage may occur. Selective reinforcement can be accomplished by any suitable treatment, such as, but not limited to, applying reinforcing structures, changing material properties, or a combination thereof.

[0080] Figure 4 From Figure 3 The schematic cross-sectional view of the spar 106 seen along section line IV-IV. For clarity, the spar 106 shown does not include the airfoil portion 102. Figure 3The spar 106 includes a spar body 124 having a peripheral surface 126. The spar 106 includes a spar centerline 122. As shown, the spar 106 includes a rectangular cross-sectional region. It will be understood that the spar 106 includes a cross-sectional region of any suitable shape, such as, but not limited to, rectangular, circular, triangular, etc. The spar 106 is divided into a first radial half 158 and a second radial half 160 relative to the spar centerline 122.

[0081] The first pocket 134 and the second pocket 136 each extend continuously between two or more corresponding regions of the peripheral surface 126. Each of the first pocket 134 and the second pocket 136 includes a corresponding opening 159 disposed along the peripheral surface 126. Specifically, each of the first pocket 134 and the second pocket 136 includes two corresponding openings 159. Thus, the first pocket 134 and the second pocket 136 are each defined as a through pocket. The corresponding cavities 130 of the first pocket 134 and the second pocket 136 open on the corresponding portions of the peripheral surface 126. When disposed within the interior 118 ( Figure 3 The corresponding cavities 130 of the first pocket 134 and the second pocket 136 lead to the interior 118.

[0082] As shown, the first pocket 134 and the second pocket 136 extend between corresponding portions of the peripheral surface 126 disposed on opposite radial sides of the spar 106 (e.g., the first radial half 158 and the second radial half 160). However, it will be understood that the first pocket 134 and the second pocket 136 may extend between two or more opposite or non-opposite portions of the peripheral surface 126 (e.g., including two or more corresponding openings 159).

[0083] Figure 5 From Figure 3 The schematic cross-sectional view of the spar 106 as seen from section line VV. For illustrative purposes, the spar 106 shown does not include the airfoil portion 102. Figure 3 The spar 106 includes a spar body 124 having a peripheral surface 126. The spar 106 includes a spar centerline 122.

[0084] The third pocket 138 and the fourth pocket 140 may each extend continuously from a corresponding area of ​​the peripheral surface 126 and terminate within the spar body 124. Each of the third pocket 138 and the fourth pocket 140 includes a corresponding opening 159 disposed along the peripheral surface 126. Thus, the third pocket 138 and the fourth pocket 140 are each defined as a partially through pocket. The corresponding cavity 130 of the third pocket 138 and the fourth pocket 140 opens in a corresponding portion of the peripheral surface 126. When disposed within the interior 118 ( Figure 3 The corresponding cavities 130 of the third pocket 138 and the fourth pocket 140 lead to the interior 118.

[0085] The third pocket 138 and the fourth pocket 140 extend to any suitable distance within the spar body 124 such that they extend beyond, coincide with, or terminate before the transition between the first radial half 158 and the second radial half 160. As a non-limiting example, the third pocket 138 extends from a portion of the peripheral surface 126 on the second radial half 160 and terminates before the first radial half 158. As a non-limiting example, the fourth pocket 140 extends from a portion of the peripheral surface 126 on the first radial half 158 and terminates before the second radial half 160. In other words, the openings 159 of at least two pockets (e.g., the third pocket 138 and the fourth pocket 140) are provided along radially opposite sides of the peripheral surface 126 (e.g., the first radial half 158 and the second radial half 160). In some embodiments, the partial through-pockets may extend through 5% to 90% of the spar body.

[0086] As shown, the third pocket 138 and the fourth pocket 140 extend from opposite radial sides (e.g., the first radial half 158 and the second radial half 160) of the peripheral surface 126 relative to the spar centerline 122. In other words, the corresponding opening of the fourth pocket 140 is located on the portion of the peripheral surface 126 radially opposite to the corresponding opening of the third pocket 138 relative to the spar centerline 122. However, it will be understood that the third pocket 138 and the fourth pocket 140 may extend from the same radial side of the peripheral surface 126. As a non-limiting example, both the third pocket 138 and the fourth pocket 140 may extend from either the first radial half 158 or the second radial half 160.

[0087] Figure 6 From Figure 3 The schematic cross-sectional view of the spar 106 shown is taken from section line VI-VI. For illustrative purposes, the spar 106 shown does not include the airfoil portion 102. Figure 3 The spar 106 includes a spar body 124 having a peripheral surface 126. The spar 106 includes a spar centerline 122.

[0088] The fifth pocket 142 may have an extension different from that of the sixth pocket 144. As a non-limiting example, the fifth pocket 142 may be a partially open pocket with a corresponding opening 159, while the sixth pocket 144 may be an open pocket with two corresponding openings 159.

[0089] Figure 7 From Figure 3The schematic cross-sectional view of spar 106 seen along section lines VII-VII. Spar 106 includes a spar body 124 having a peripheral surface 126. Spar 106 includes a spar centerline 122. A seventh pocket 146 may be completely disposed within the spar body 124. Therefore, the seventh pocket 146 may be defined as an internal pocket. In some embodiments, the seventh pocket 146 may extend less than 50%, 20%, 10%, or 5% of Lps.

[0090] Figure 4-7 Various non-limiting configurations of the group of pockets 128 are shown. In some embodiments, each pocket in the group of pockets 128 includes the same corresponding configuration between the pockets. In some embodiments, each pocket in the group of pockets 128 includes different corresponding configurations between the pockets. Non-limiting examples of the configurations of the group of pockets 128 will be described in more detail below; however, each pocket in the group of pockets 128 may include a corresponding configuration such that the pocket is one of a through pocket, a partially through pocket, or an inner pocket.

[0091] It will be understood that the construction of the corresponding pockets in the group of pockets 128 can vary along the corresponding pocket. As a non-limiting example, the corresponding pocket may include a first position and a second position, the second position being in Figure 2 Wingspan direction (Sd) Figure 2 The corresponding pocket is spaced apart from the first position in at least one of the chordal direction (Cd) or combinations thereof. The corresponding pocket can be one of a full pocket, a partially full pocket, or an inner pocket at the first position. The corresponding pocket can be another of a full pocket, a partially full pocket, or an inner pocket at the second position. In this case, the first position is axially spaced apart from the second position along the spar centerline 122. Alternatively, the corresponding pocket can be fully formed as one of a full pocket, a partially full pocket, or an inner pocket.

[0092] The benefits of this disclosure include an airfoil assembly that is lighter than conventional airfoil assemblies without sacrificing the structural integrity of conventional airfoil assemblies. For example, a conventional airfoil assembly may include a spar with a spar body having a solid material or a solid material mass with a single average density. However, the spar described herein includes a spar with a set of pockets having a lower density material than the spar body. If a conventional spar and the spar described herein are the same size, the reduced density region results in a lighter spar compared to a conventional spar. Furthermore, the formation of the spar (e.g., an oval or spherical three-dimensional shape, or including filler material) ensures that the set of pockets does not create a region of reduced strength within the spar. In other words, the set of pockets does not sacrifice the structural integrity of the spar compared to a conventional spar.

[0093] These pockets are designed to reduce the overall weight of the component and are tailored to minimize the impact on the overall stiffness of the airfoil assembly. By adding pockets within the spars, the impact on the overall stiffness of the airfoil is minimized. The shape of the pockets can be designed to minimize stress concentration due to point stresses. The pockets can be filled with a low-density material (such as foam) to prevent excessive resin from entering these areas during manufacturing.

[0094] Within the scope not described herein, various features and structures of the various embodiments may be combined or interchanged as needed. All combinations or arrangements of the features described herein are covered by this disclosure.

[0095] 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.

[0096] Further details are provided by the following topics:

[0097] An airfoil assembly includes: an airfoil portion having an outer wall extending in a spanwise direction between a root and a tip, and between a leading edge and a trailing edge, the outer wall defining an interior of the airfoil portion; and a spar connected to the airfoil portion and extending into the interior, the spar including a spar centerline, a spar body defining a peripheral surface, and a plurality of pockets disposed within the spar body, each of the plurality of pockets forming a corresponding cavity within the spar body.

[0098] According to any of the foregoing clauses, in the airfoil assembly, at least one of the plurality of pockets is a partially open pocket having a corresponding opening disposed along the peripheral surface.

[0099] According to any of the foregoing clauses, at least one of the plurality of pockets is a through pocket that extends through the spar body between at least two corresponding openings disposed along the peripheral surface.

[0100] According to any of the foregoing clauses, the airfoil assembly wherein the at least two corresponding openings are arranged radially opposite sides of the peripheral surface relative to the centerline of the spar.

[0101] According to any of the foregoing clauses, at least one of the plurality of pockets is an internal pocket that is completely disposed within the sparsity body.

[0102] According to any of the foregoing clauses, the plurality of pockets includes: a first pocket including at least one corresponding opening disposed along the peripheral surface, the first pocket being at least a partially through pocket; and a second pocket separate from the first pocket, the second pocket having at least one corresponding opening disposed along the peripheral surface, the second pocket being a partially through pocket or an internal pocket.

[0103] According to any of the foregoing clauses, the airfoil assembly wherein: the first pocket and the second pocket are each partially through pockets; and the corresponding opening of the first pocket is disposed on the peripheral surface radially opposite to the corresponding opening of the second pocket, relative to the centerline of the spar.

[0104] According to any of the foregoing clauses, the airfoil assembly includes a first pocket and a second pocket, wherein the volume of the first pocket is greater than the volume of the second pocket, and the first pocket is axially positioned relative to the centerline of the spar closer to the root of the airfoil portion than the second pocket.

[0105] According to any of the foregoing clauses, the plurality of pockets includes a first pocket and a last pocket, the first pocket being the one axially positioned closest to the root, and the last pocket being the one axially positioned furthest from the root, wherein the size of the corresponding volume of each of the plurality of pockets increases continuously from the first pocket to the last pocket.

[0106] According to any of the foregoing clauses, the airfoil assembly wherein:

[0107] The spar includes an inner portion disposed within the interior of the airfoil portion, the inner portion extending the inner length of the spar in the span direction;

[0108] The plurality of pockets extend relative to the centerline of the spar by a pocket extension length, the pocket extension length being defined as the total axial distance occupied by a set of pockets along the spar, and the pocket extension length being greater than or equal to 0.1% and less than or equal to 100% of the inner length of the spar.

[0109] According to any of the foregoing clauses, the sill extension length is greater than or equal to 0.1% and less than or equal to 10% of the internal length of the spar.

[0110] According to any of the foregoing clauses, the airfoil portion extends a span length in the span direction between the root and the tip, and the spar extends between 30% and 100% of the span length (including the endpoint).

[0111] According to any of the foregoing clauses, the airfoil assembly wherein at least one of the plurality of pockets includes a filling material.

[0112] According to any of the foregoing clauses, the plurality of pockets have at least two pockets, and the at least two pockets have different filling materials.

[0113] According to any of the foregoing clauses, in the airfoil assembly, at least one of the plurality of pockets does not include the filling material.

[0114] According to any of the foregoing clauses, the airfoil assembly is a composite prefabricated component including the plurality of pockets.

[0115] According to any of the foregoing clauses, the airfoil portion and the spar each comprise a composite material.

[0116] According to any of the foregoing clauses, the airfoil assembly wherein the corresponding cavity is oval.

[0117] A turbine engine includes: an engine core having a compressor section, a combustion section and a turbine section arranged in a series flow configuration, the engine core defining a rotor and a stator; a fan section coupled to the rotor; and an airfoil assembly according to any of the preceding clauses, the airfoil assembly being disposed within at least one of the engine core or the fan section.

[0118] According to any of the preceding clauses, the turbine engine, wherein the fan section includes a set of outer fan blades and a set of outer fan wheel blades, and the airfoil assembly is disposed within the set of outer fan blades or the set of outer fan wheel blades.

[0119] According to any of the foregoing clauses, at least one of the plurality of pockets is a machined pocket.

[0120] According to any of the foregoing clauses, in the airfoil assembly, at least one of the plurality of pockets has a volume defined as a rectangular prism.

[0121] According to any of the foregoing clauses, in the airfoil assembly, at least one of the plurality of pockets has a volume defined as a pyramid.

[0122] According to any of the foregoing clauses, in the airfoil assembly, at least one of the plurality of pockets has a volume defined as a sphere.

[0123] According to any of the foregoing clauses, at least one of the plurality of pockets is a single continuous pocket.

[0124] According to any of the foregoing clauses, the single continuous pocket is the only pocket of the spar located within the interior.

[0125] The airfoil assembly according to any of the foregoing clauses further includes a sleeve extending on a corresponding portion of the peripheral surface.

[0126] According to any of the foregoing clauses, the airfoil assembly wherein the sleeve extends into the interior.

[0127] According to any of the foregoing clauses, in the airfoil assembly, at least one of the plurality of pockets is disposed outside the region of the spar surrounded by the sleeve.

[0128] According to any of the foregoing clauses, in the airfoil assembly, at least one of the plurality of pockets is disposed in the region of the spar surrounded by the sleeve.

[0129] According to any of the foregoing clauses, the airfoil assembly has at least two pockets, and the at least two pockets have corresponding volumes defined by different shapes.

[0130] According to any of the foregoing clauses, the airfoil assembly wherein the plurality of pockets are defined by a pocket density, wherein the pocket density varies axially along the centerline of the spar.

[0131] According to any of the foregoing clauses, the density of the pocket near the root is greater than the density of the pocket near the distal end.

[0132] The airfoil assembly according to any of the foregoing clauses further includes a filling material disposed within the cavity, the filling material occupying a volume smaller than the corresponding volume defined by at least one of the plurality of pockets.

[0133] According to any of the foregoing clauses, the airfoil assembly is cast together with at least one of the plurality of pockets.

[0134] According to any of the foregoing clauses, the airfoil assembly is 3D printed together with at least one of the plurality of pockets.

[0135] According to any of the foregoing clauses, the airfoil assembly is solidified together with at least one of the plurality of pockets.

[0136] According to any of the foregoing clauses, the airfoil assembly wherein the at least two pockets are contained within a plurality of pockets, the plurality of pockets having different densities in local regions of the spar body.

Claims

1. An airfoil component assembly, characterized in that, include: An airfoil portion having an outer wall extending in the span direction between a root and a tip, and between a leading edge and a trailing edge, the outer wall defining the interior of the airfoil portion; as well as A spar, which is connected to the airfoil portion and extends into the interior, the spar including a spar centerline, a spar body defining a peripheral surface, and a plurality of pockets disposed within the spar body, each of the plurality of pockets forming a corresponding cavity within the spar body.

2. The airfoil assembly according to claim 1, characterized in that, in, At least one of the plurality of pockets is a partially open pocket, the partially open pocket having a corresponding opening disposed along the peripheral surface.

3. The airfoil assembly according to claim 1, characterized in that, in, At least one of the plurality of pockets is a through pocket that extends through the spar body between at least two corresponding openings provided along the peripheral surface.

4. The airfoil assembly according to claim 3, characterized in that, in, The at least two corresponding openings are arranged radially opposite sides of the peripheral surface relative to the centerline of the spar.

5. The airfoil assembly according to claim 1, characterized in that, in, At least one of the plurality of pockets is an internal pocket that is completely disposed within the spar body.

6. The airfoil assembly according to claim 1, characterized in that, in, The plurality of pockets include: A first pocket portion, the first pocket portion including at least one corresponding opening disposed along the peripheral surface, the first pocket portion being at least partially through-hole; and A second pocket portion, which is separate from the first pocket portion, has at least one corresponding opening disposed along the peripheral surface, and is either a partially open pocket portion or an internal pocket portion.

7. The airfoil assembly according to claim 6, characterized in that, in: The first pocket and the second pocket are each partially open pockets; and The corresponding opening of the first pocket is located on the peripheral surface of the wing beam centerline on the side that is radially opposite to the corresponding opening of the second pocket.

8. The airfoil assembly according to claim 1, characterized in that, in, The plurality of pockets includes a first pocket and a second pocket, wherein the volume of the first pocket is larger than the volume of the second pocket, and the first pocket is axially positioned relative to the centerline of the spar closer to the root of the airfoil portion than the second pocket.

9. The airfoil assembly according to claim 1, characterized in that, in, The plurality of pockets includes a first pocket and a last pocket, wherein the first pocket is the one axially positioned closest to the root, and the last pocket is the one axially positioned furthest from the root, wherein the size of the corresponding volume of each of the plurality of pockets increases continuously from the first pocket to the last pocket.

10. A turbine engine, characterized in that, include: An engine core having a compressor section, a combustion section and a turbine section arranged in a series flow, the engine core defining a rotor and a stator; A fan section, the fan section being connected to the rotor; as well as According to claim 1, the airfoil assembly is disposed within at least one of the engine core or the fan section.

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