Turbine engine for aircraft with integral frame

Abstract

A turbine engine for an aircraft includes a unitary frame. The unitary frame includes an inner hub, a frame housing having an outer strap portion and a receiving portion integrally formed with the outer strap portion, and a plurality of struts connecting the inner hub and the outer strap portion. The outer band is opposite the inner hub to form an air flow path therebetween, and the receiving portion extends away from the outer band in an axial direction of the turbine engine. The receiving portion is positioned radially outward of the plurality of rotary wings and extends axially over the plurality of rotary wings. The outer band portion and the containment portion of the frame shell may be a monolithic composite having a plurality of reinforcing fibers embedded in a matrix or a monolithic metal portion.

Description

Cross-references to related applications

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 715,150, filed November 1, 2024, the entire contents of which are incorporated herein by reference. Technical Field

[0002] This disclosure relates to the framework of a turbine engine, and in particular to a turbine engine for an aircraft. Background Technology

[0003] Turbine engines used in aircraft typically consist of a fan, compressor section, combustion section, and turbine section. The combustor in the combustion section produces combustion gases to drive one or more turbines in the turbine section, which in turn drive the fan. A portion of the air flowing into the fan serves as core air, passing through the compressor, combustion, and turbine sections; another portion flows as bypass air, bypassing these sections and through the turbine engine. The compressor section may include one or more compressors, or be turbine-driven, to compress core air before it flows into the combustor. Composite materials can be used to manufacture various components of turbine engines, especially when the turbine engine is for an aircraft. Attached Figure Description

[0004] The features and advantages of this disclosure will be apparent from the following description of various exemplary embodiments, as shown in the accompanying drawings, wherein similar reference numerals generally indicate the same elements or elements that are structurally or functionally similar.

[0005] Figure 1 This is a schematic cross-sectional view of the aircraft's turbine engine.

[0006] Figure 2A This is a cross-sectional view of a part of a turbine engine, showing... Figure 1 Details 2A.

[0007] Figure 2B From similar Figure 1 A cross-sectional view of a portion of a turbine engine taken from the perspective of detail 2A.

[0008] Figure 3 It can be used Figure 1 The diagram shows a cross-sectional view of the shiplap joint of the engine's integral frame.

[0009] Figure 4 It can be used Figure 1 The diagram shows a cross-sectional view of the lap joint of the engine's integral frame.

[0010] Figure 5 It can be used Figure 1The diagram shows a cross-sectional view of the lap joint of the engine's integral frame. Detailed Implementation

[0011] The features, advantages, and embodiments of this disclosure will be set forth or apparent from the following detailed description, drawings, and claims. Furthermore, the following detailed description is exemplary and intended to provide further explanation without limiting the scope of the claimed disclosure.

[0012] Various embodiments are discussed in detail below. Although specific embodiments are discussed, they are for illustrative purposes only. Those skilled in the art will recognize that other components and configurations can be used without departing from this disclosure.

[0013] As used herein, the terms “first,” “second,” and “third” are used interchangeably to distinguish one component from another, rather than to indicate the location or importance of individual components.

[0014] The terms "upstream" and "downstream" refer to the relative directions of fluid flow in a fluid path. For example, "upstream" means the direction from which the fluid flows, and "downstream" means the direction from which the fluid flows.

[0015] As used herein, the terms "axial" and "axially" refer to a direction and orientation that extends substantially parallel to the centerline of the turbine engine. Furthermore, the terms "radial" and "radially" refer to a direction and orientation that extends substantially perpendicular to the centerline of the turbine engine. Additionally, as used herein, the terms "circumferential" and "circumferentially" refer to a direction and orientation that extends in an arc around the centerline of the turbine engine.

[0016] The terms “connection,” “fixation,” “attachment,” “linkage,” etc., refer to direct connection, fixation, attachment, or linking, as well as indirect connection, fixation, attachment, or linking through one or more intermediate parts or features, unless otherwise specified herein.

[0017] Unless the context clearly indicates otherwise, the singular forms “a,” “one,” and “the” include plural references.

[0018] In this specification and claims, scope limitations are combined and interchanged. Unless the context or language otherwise indicates, these scopes are identified and all subscopes contained therein are included. For example, all scopes disclosed herein include endpoints, and endpoints may be combined independently of each other.

[0019] As used in this article, the term "fastening" refers to the use of mechanical means (such as screws, bolts, adhesives, brazing, welding or other methods) to securely attach or connect two or more components together to ensure their stability and integrity in their assembled state.

[0020] The term “monolithic” as used in this article, when applied to components or structures, refers to a component or structure formed from a single piece of material, such as a sheet of metal, without joints or seams.

[0021] As used in this document, the term "monolithic" refers to a component or structure that is formed as a single, unified component or structure. Other components may be fastened to the monolithic structure or component, but the monolithic component or structure itself does not include the fastening components or structures. A monolithic component or structure is a single-piece component or structure.

[0022] As used herein, the terms "additive manufacturing" and "additive manufacturing technology or process" generally refer to a manufacturing process in which continuous layers of material are provided on one another to "stack" a three-dimensional part layer by layer. Continuous layers are typically fused together to form a monolithic part that can have a variety of integral sub-components. While additive manufacturing technology may be described herein as capable of manufacturing complex objects by building them point-by-point, layer-by-layer, typically in a vertical direction, other manufacturing methods are possible and within the scope of this subject matter. For example, although this discussion relates to adding material to form continuous layers, any additive manufacturing technology or manufacturing technique can be employed to implement the methods and structures disclosed herein. For example, embodiments of this disclosure may use layer additive processes, layer subtractive processes, or hybrid processes.

[0023] As used herein, the term "composite material" refers to a material having two or more constituent materials. A composite material can be a combination of at least two or more metals, nonmetals, or metal and nonmetal elements or materials. Examples of composite materials include, but are not limited to, polymer matrix composites (PMCs), ceramic matrix composites (CMCs), and metal matrix composites (MMCs). Composite materials can be formed from a matrix material and reinforcing elements or reinforcing materials, such as fibers (referred to herein as reinforcing fibers).

[0024] As used herein, "reinforcing fiber" can include, for example, glass fiber, carbon fiber, steel fiber, or aramid fiber, such as Kevalle®, available from DuPont in Wilmington, Delaware. Reinforcing fiber can be in the form of a fiber bundle comprising multiple fibers forming a bundle.

[0025] As used herein, "composite component" refers to a structure or part that comprises any suitable composite material. A composite component, such as a composite airfoil, may comprise several layers or layups of composite material. The layers or layups may vary in stiffness, material, and size to achieve a desired composite component or composite portion of a component having predetermined weight, size, stiffness, and strength. One or more layers of adhesive may be used to form or bond the composite component. The adhesive may require curing at high temperatures or other curing techniques.

[0026] As used herein, a “preform” refers to a shaped or formable arrangement of reinforcing fibers configured to define at least a portion of a composite component prior to resin infiltration, curing, or consolidation. Reinforcing fibers may be provided in various forms, including but not limited to two-dimensional woven fabrics, three-dimensional woven fabrics, braided fabrics, stitched fabrics, knitted fabrics, nonwoven felts, unidirectional tapes, or combinations thereof. A preform may comprise multiple layers or layups, may incorporate stitching, adhesive materials, or tackifiers to maintain a desired geometry, and may be a near-net-shape component or provided as part of an assembly or subassembly for subsequent processing.

[0027] As used herein, PMC refers to a class of materials, and more specifically, a class of composite materials using a polymer matrix. Resins can be used as matrix materials for PMCs and are generally classified as thermosetting or thermoplastic resins. Thermoplastic resins are typically classified as polymers that repeatedly soften and flow upon heating, but 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 considered for aerospace applications include polyetheretherketone (PEEK), polyetherketoneketone (PEKK), polyetherimide (PEI), polyaryletherketone (PAEK), and polyphenylene sulfide (PPS). In contrast, thermosetting resins do not soften significantly 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] PMC materials can be prepregs. Prepregs are reinforcing materials (e.g., reinforcing fibers) pre-impregnated with a polymer matrix material. Non-limiting examples of polymer prepreg manufacturing processes include hot melt prepreg and powder prepreg, in which molten resin is deposited onto the fiber reinforcing material, and in which resin is deposited onto the fiber reinforcing material by an electrostatic method (non-limiting example), and then the resin is bonded to the fibers by means of an oven or with the assistance of heated rollers (non-limiting example).

[0029] Another non-limiting example uses dry reinforcing fibers instead of a prepreg containing thermoplastic polymers. Dry reinforcing fibers can be positioned to form a preform. For example, reinforcing fibers, more specifically, bundles of reinforcing fibers, can be woven together as a braided fabric. The braided fabric can be, but is not limited to, entirely woven from dry carbon fibers or woven from dry carbon fibers with polymer fibers or filaments. Non-prepreg braided structures can be constructed in a similar manner. In this way, the fiber volume of the part can be customized by specifying the relative concentrations of the thermoplastic fibers and reinforcing fibers already woven or braided together. Furthermore, different types of reinforcing fibers can be braided or woven into 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, glass fibers can be combined to enhance impact characteristics, a design feature of parts near the engine inlet, and thermoplastic fibers provide the binding of the reinforcing fibers.

[0030] 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 dry fibers to a mold or cavity. The dry fibers can include braided materials, woven materials, or any combination thereof. Resin can be pumped in or otherwise supplied to the mold or cavity to impregnate the dry fibers. The impregnated fiber and resin combination is then cured and removed from the mold. As mentioned above, the matrix material can include thermoplastic and thermosetting resins. The composite part may require post-curing treatment upon removal from the mold. RTM can be a vacuum-assisted process. That is, air in the cavity or mold can be removed and replaced with resin before heating or curing. The placement of the dry fibers can be manual or automatic. The dry fibers can be contoured to form the composite part or guide the resin. Optionally, additional layers or reinforcing layers of a different material from the dry fibers can be added or incorporated before heating or curing.

[0031] As used herein, the term "metal" refers to a metal-based material, including, but not limited to, metals such as, but not limited to, titanium, iron, aluminum, stainless steel, and nickel alloys. A metallic material or metal alloy may be a combination of at least two or more elements or materials, at least one of which is a metal.

[0032] As used herein, an alloy is "based on" a particular element when that element is present in the alloy at the largest weight percentage of the alloy's total weight relative to all elements contained in the alloy. For example, an iron-based alloy has a higher weight percentage of iron than any other single element present in that alloy.

[0033] A turbine engine for an aircraft may include various airflow paths. These airflow paths may be defined, at least in part, by multiple shell structures. Adjacent shell structures may be attached to each other to form the airflow paths. The more shell structures used to define the airflow paths, the more joints required to connect these shell structures, increasing the complexity and weight of the turbine engine—a consideration in aircraft turbine engine design. The turbine engine may also include rotating airfoil assemblies, such as fan or compressor rotors, which include rotating airfoils. A shell may surround the rotating airfoil. In addition to defining a portion of the airflow path, the shell may also be a receiving structure for holding broken blades or blade fragments therein. Furthermore, the turbine engine may include a frame that supports various components and defines a portion of the airflow path. This document discloses a frame integrally formed with adjacent shell structures, reducing the weight and complexity of the shells defining the airflow paths. More specifically, the frame includes an outer band integrally formed with adjacent shell structures, such as a receiving shell surrounding a rotating airfoil assembly (e.g., a fan). Various joints, such as lap joints, are also discussed here for connecting an integral frame, such as a receiving shell portion, to an adjacent shell.

[0034] As described above, certain components of gas turbine engines, particularly those used in aircraft, can be made of composite materials. Such components can include, for example, various frames, struts, airfoils, shell structures, and housing structures. For example, the housing surrounding a rotating airfoil assembly, such as a fan or compressor rotor, including the rotating airfoil, can be made of composite materials. Housings incorporating composite materials provide significant weight savings for the turbine engines of aircraft. Similarly, engine frames can include composite materials. Composite materials can be used to form the integral frame structures disclosed herein, and the joints described herein can be used with these composite housings.

[0035] Figure 1 This is a schematic cross-sectional view of a turbine engine 100 that can be used in an aircraft. The turbine engine 100 extends in an axial direction A (parallel to the longitudinal centerline (axis) 101, as shown below). Figure 1 As shown), the radial direction R and the circumferential direction C. The circumferential direction C extends in the direction of rotation about the longitudinal centerline (axis) 101 (axial direction A). Figure 1 In the illustrated embodiment, the turbine engine 100 is a ductless fan engine or an open fan engine. The turbine engine 100 is a "three-flow engine," having three distinct flows of air (in...) during operation that generate thrust. Figure 1 (Called S1, S2, and S3), as described below. The turbine engine 100 includes a fan section 102.

[0036] Figure 1The illustrated turbine engine 100 includes a compressor section 110, a combustion section 120, and a turbine section 130 in a serial flow relationship. The compressor section 110, combustion section 120, and turbine section 130 are located downstream of the fan section 102. The compressor section 110, combustion section 120, and turbine section 130 are substantially enclosed within a core shroud 106, which is substantially tubular and annularly surrounds the compressor section 110, combustion section 120, and turbine section 130. The core shroud 106 defines a core inlet 141, which, in this embodiment, is annular. Figure 1 As schematically shown, compressor section 110 includes a turbocharger or low-pressure (LP) compressor 112, downstream of which follows a high-pressure (HP) compressor 114. Combustion section 120 is located downstream of compressor section 110. Turbine section 130 is located downstream of combustion section 120 and includes a high-pressure (HP) turbine 132, downstream of which follows a low-pressure (LP) turbine 134. Turbine engine 100 also includes a core air exhaust nozzle 143 (also referred to as an injection exhaust nozzle) located downstream of turbine section 130. Compressor section 110, combustion section 120, and turbine section 130 together at least partially define a core air flow path, also referred to as core duct 140, extending from core inlet 141 to core air exhaust nozzle 143, through which core air A5 flows. As will be discussed in more detail below, turbine engine 100 includes a high-pressure (HP) shaft 108 and a low-pressure (LP) shaft 109. HP shaft 108 drives HP turbine 132 to HP compressor 114. HP turbine 132 and HP compressor 114 rotate synchronously via HP shaft 108. LP shaft 109 drives LP turbine 134 to LP compressor 112. LP turbine 134 and LP compressor 112 rotate synchronously via LP shaft 109.

[0037] Each of the LP compressor 112 and HP compressor 114 may include multiple compressor stages. In each stage, multiple compressor blades 116 rotate relative to corresponding multiple static compressor impeller blades 118 (also referred to as nozzles) to compress or pressurize the core air A5 through that stage. In a single compressor stage, the multiple compressor blades 116 may be arranged in annular shape, extending radially outward from the blade platform to the blade tip relative to a longitudinal centerline (axis) 101 (e.g., extending radially R). The compressor blades 116 may be part of a compressor rotor including a disk, wherein the compressor blades 116 extend radially from the disk. Other configurations of the compressor rotor may be used, including, for example, wherein the disk and compressor blades 116 are integrally formed as a single piece of integral bladed disk. The corresponding static compressor impeller blades 118 are positioned upstream of and adjacent to the rotating compressor blades 116. The compressor impeller blades 118 of the compressor stage may be circumferentially arranged and mounted on a core housing 107. The core housing 107 may at least partially define a core airflow path (core duct 140). Each compressor stage can be used to sequentially compress core air A5 flowing through the core airflow path (core duct 140) to produce compressed air A6. Any suitable number of compressor blades 116, compressor impellers 118, and compressor stages can be used.

[0038] Each of the HP turbine 132 and LP turbine 134 may also include multiple turbine stages. In each stage, multiple turbine blades 136 rotate relative to corresponding multiple static turbine blades 138 (also referred to as nozzles) to extract energy from the combustion gas A7 passing through the stage. The turbine blades 136 may be part of a turbine rotor. Any suitable configuration of the turbine rotor may be used, including, for example, a disk having multiple turbine blades 136 extending from a disk. The corresponding static turbine blades 138 are positioned upstream of and adjacent to the rotating turbine blades 136. The turbine blades 138 of the turbine stages may be circumferentially arranged and mounted on the core housing 107.

[0039] In combustion section 120, fuel received from the fuel system (not shown) is injected through fuel nozzle 126 into combustion chamber 124 of combustor 122. The fuel mixes with compressed air A6 from compressor section 110 to form a fuel-air mixture, which is then combusted to produce combustion products (i.e., combustion gases A7). As described below, adjusting the fuel metering unit (not shown) of the fuel system alters the volume of fuel supplied to combustion chamber 124, thereby changing the amount of thrust generated by turbine engine 100 to propel the aircraft. Combustion gases A7 are discharged from combustion chamber 124. These combustion gases can be directed into turbine blades 136 of HP turbine 132, and then turbine blades 136 of LP turbine 134, and the combustion gases A7 drive (rotate) the turbine blades 136 of HP turbine 132 and LP turbine 134. Any suitable number of turbine blades 136, turbine wheel blades 138, and turbine stages can be used. After flowing through turbine section 130, combustion gases A7 are discharged from turbine engine 100 through core exhaust nozzle 143 to provide propulsive thrust.

[0040] The turbine engine 100 further includes one or more drive shafts. As described above, the HP shaft 108 drives the HP turbine 132 to the HP compressor 114, and the LP shaft 109 drives the LP turbine 134 to the LP compressor 112. More specifically, the turbine rotor of the HP turbine 132 is connected to the HP shaft 108, and the compressor rotor of the HP compressor 114 is connected to the HP shaft 108. Combustion gas A7 is directed into the HP turbine 132 and expanded therethrough, wherein a portion of the kinetic energy from the combustion gas A7 is extracted via one or more stages of the turbine blades 136 and turbine wheel blades 138 of the HP turbine 132. This causes the HP shaft 108 to rotate, which supports the operation of the HP compressor 114 (self-sustaining cycle), and rotates the compressor rotor and thus the compressor blades 116 of the HP compressor 114. In this way, the combustion gas A7 performs work on the HP turbine 132. The combustion gas A7 is then directed into the LP turbine 134 and expanded therethrough. Here, a second portion of the kinetic energy is extracted from the combustion gas A7 via one or more stages of the turbine blades 136 and turbine vanes 138 of the LP turbine 134. This causes the LP shaft 109 to rotate, which supports the operation of the LP compressor 112 (self-sustaining cycle), and rotates the compressor rotor and thus the compressor blades 116 of the LP compressor 112. In this way, the combustion gas A7 does work on the LP turbine 134. The HP shaft 108 and the LP shaft 109 are coaxially arranged about the longitudinal centerline axis 101. The diameter of the HP shaft 108 is larger than the diameter of the LP shaft 109, and the HP shaft 108 is located radially outside the LP shaft 109. The HP shaft 108 and the LP shaft 109 are rotatable about the longitudinal centerline (axis) 101 and, as described above, are connected to rotatable elements such as the compressor rotor and the turbine rotor.

[0041] Figure 1 The fan section 102 shown includes a fan, referred to herein as the main fan 150. In the described embodiment, the main fan 150 is an open rotor fan, also known as a ductless fan. The main fan 150 has a plurality of main fan blades 151 coupled to a fan disk 153. Figure 1 As shown, the main fan blades 151 extend outward from the fan disk 153 in a roughly radial direction R. Figure 1 A single main fan blade 151 is depicted, but multiple main fan blades 151 can be arranged at equal intervals around a longitudinal centerline axis 101. The main fan blades 151 and the fan disk 153 are capable of rotating together about the longitudinal centerline (axis) 101 via a fan shaft 155. The fan disk 153 is covered by a fan hub 157, which has an aerodynamic profile to facilitate airflow through the multiple main fan blades 151. In this embodiment, the fan hub 157 is capable of rotating together with the main fan blades 151 and the fan disk 153.

[0042] like Figure 1 As shown, the fan shaft 155 is connected to the LP shaft 109 via a reduction gearbox or power gearbox (also referred to as gearbox assembly 159). Therefore, the LP shaft 109 is driven by the main fan. The gearbox assembly 159 is... Figure 1 The diagram is schematically shown. Gearbox assembly 159 includes multiple gears for adjusting the rotational speed of fan shaft 155, thereby adjusting the rotational speed of main fan 150 relative to LP shaft 109. Gearbox assembly 159 can be used to reduce the rotational speed to a more efficient speed for main fan 150. Gearbox assembly 159 can have a gear ratio of 4:1 to 12:1, or 7:1 to 12:1, or 4:1 to 10:1, or 5:1 to 9:1, or 6:1 to 9:1, and can be configured in a planetary or corona configuration. Gearbox assembly can have a gear ratio of 4:1 to 10:1 for ductless fan engines (e.g., turbine engine 100). The gearbox can be a single-stage gearbox or a compound gearbox (e.g., multi-stage).

[0043] In the case of variable pitch fans, such as Figure 1 As shown, for example, multiple main fan blades 151 are rotatable relative to the fan disk 153 about the fan blade pitch axis PB. Each main fan blade 151 is connected to the fan disk 153 via a pitch bearing 162, which allows the main fan blade 151 to rotate about the pitch axis PB. The main fan blade 151 is rotatable within the pitch bearing 162 by a pitch actuator 164 operably coupled to the main fan blade 151 to change the pitch of the corresponding main fan blade 151. One or more pitch actuators 164 may be used, and in some embodiments, the pitch actuators 164 rotate the main fan blades 151 uniformly. The fan actuation system 160 controls one or more pitch actuators 164 to change the pitch of the main fan blades 151 about their respective pitch axes PB. The fan actuation system 160 may be disposed within the fan hub 157. Additionally, or alternatively, a portion of the fan actuation system 160 may be disposed within the inner hub housing 105. The gearbox assembly 159 and other parts of the main fan 150 can be housed within the inner hub housing 105.

[0044] Fan section 102 includes multiple fan guide vanes 172 ( Figure 1 (Only one is shown in the image). Fan guide vanes 172 are circumferentially spaced and arranged around the longitudinal centerline axis 101, as part of the fan guide vane array 170. Figure 1In the illustrated embodiment, the fan guide vane 172 is a static airfoil that cannot rotate about the longitudinal centerline (axis) 101. Each fan guide vane 172 is mounted on the fan shroud 174 and extends outward from the fan shroud 174 generally along the radial direction R. In the case of a variable pitch fan, as... Figure 1 As shown, for example, multiple fan guide vanes 172 are rotatable relative to the fan shroud 174 about the fan guide vane pitch axis PV. A fan guide vane actuation system 166 can be used to change the pitch of the fan guide vanes 172. The fan guide vane actuation system 166 can operate similarly to the fan actuation system 160 described above, and the discussion herein applies. Therefore, the same reference numerals are used for the pitch bearing 162 and the pitch actuator 164 of the fan guide vane actuation system 166.

[0045] A fan shroud 174 annularly surrounds at least a portion of the core shroud 106 and is positioned generally along the radial direction R outside the core shroud 106. Together, the fan shroud 174 and the core shroud 106 define the outer casing of the turbine engine 100. A downstream section of the fan shroud 174 extends to the front of the core shroud 106 to define a fan flow path, also referred to as a fan duct 181. Incoming air enters through the fan duct inlet 183, passes through the fan duct 181, and exits through the fan exhaust nozzle 185 to generate propulsive thrust. The fan duct 181 is an annular duct positioned generally along the radial direction R outside the core duct 140. The fan shroud 174 and the core shroud 106 are connected together and are supported by a plurality of struts 176 ( Figure 4 (Only one is shown in the image) Supports. Struts 176 are circumferentially spaced around a longitudinal centerline (axis) 101 and extend radially outward from the core shroud 106. Each of the plurality of struts 176 has an aerodynamic profile to guide the airflow therefrom.

[0046] The turbine engine 100 includes an inlet duct 187. The inlet duct 187 extends between an engine inlet 189, a core inlet 141, and a fan duct inlet 183. The engine inlet 189 is generally defined at the front end of a fan shroud 174 and is positioned along the axial direction A between a main fan 150 and a fan guide vane 172. The inlet duct 187 is an annular duct positioned along the radial direction R inside the fan shroud 174. Air flowing downstream of the inlet duct 187 is split (not necessarily uniformly) by a splitter 178 of the core shroud 106 into the core duct 140 and the fan duct 181. The inlet duct 187 is wider than the core duct 140 in the radial direction R, and also wider than the fan duct 181 in the radial direction R.

[0047] Fan section 102 further includes an intermediate fan 190. The intermediate fan 190 includes a plurality of intermediate fan blades 192 ( Figure 4(Only one is shown). A plurality of intermediate fan blades 192 are rotatable about a longitudinal centerline axis 101. In the described embodiment, the intermediate fan 190 is drivenly coupled to the LP turbine 134 via an LP shaft 109. The plurality of intermediate fan blades 192 may be arranged at equal circumferential spacing about the longitudinal centerline axis 101. The intermediate fan blades 192 may be part of a rotor that includes a central hub, such as a disk 194, and each of the plurality of intermediate fan blades 192 extends radially from the disk 194. Other configurations of the compressor rotor may be used, including, for example, where the disk 194 and the intermediate fan blades 192 are integrally formed as a single piece of a monolithic bladed disk.

[0048] Multiple intermediate fan blades 192 are annularly surrounded (e.g., ducted) by a fan shroud 174. In this respect, an intermediate fan 190 is positioned radially R inside the fan shroud 174. The intermediate fan 190 is positioned within an inlet duct 187 upstream of the core duct 140 and the fan duct 181. The ratio of the span (measured from root to tip) of the main fan blade 151 to the intermediate fan blades 192 is greater than two and less than ten to achieve the desired benefits of a third flow (S3), specifically, the additional thrust provided by the third flow (S3) to the engine, enabling the smaller diameter main fan blades 151. Multiple inlet intermediate fan blades 196 are positioned upstream of and adjacent to the rotating intermediate fan blades 192. The inlet intermediate fan blades 196 may be circumferentially arranged and mounted on the fan shroud 174.

[0049] The fan shroud 174 can also be connected to the inner hub housing 105 and supported by a frame, such as a monolithic frame 200. The monolithic frame 200 may include multiple struts 210 ( Figure 1 (Only one is shown in the image). The struts 210 are circumferentially spaced about the longitudinal centerline axis 101 and extend radially outward from the inner hub housing 105. Each of the multiple struts 210 has an aerodynamic profile to guide the airflow therefrom.

[0050] During operation of the turbine engine 100, the initial airflow, or incoming air A1, passes through the main fan blades 151 of the main fan 150 and is split into a first airflow (first portion of air, referred to herein as main bypass air A2) and a second airflow (second portion of air, referred to herein as engine air A3). The main bypass air A2 bypasses the engine inlet 189 and flows outward from the fan shroud 174, generally along the axial direction A and radial direction R. The main bypass air A2 is accelerated by the main fan blades 151 and passes through the fan guide vanes 172. The main bypass air A2 then continues downward to generate the main propulsion flow, or first thrust flow S1. The majority of the net thrust generated by the turbine engine 100 is generated by the first thrust flow S1.

[0051] Engine air A3 is directed or directed to inlet duct 187 and enters inlet duct 187 through engine inlet 189. Downstream of inlet duct 187, engine air A3 flows through the intermediate fan blades 192 of intermediate fan 190 and is compressed by the rotating intermediate fan blades 192. After passing through the intermediate fan blades 192, engine air A3 is split by splitter 178 into a third airflow (third portion air, referred to herein as secondary bypass air A4) and a fourth airflow (fourth portion air, referred to herein as core air A5). Core air A5 is directed or directed to the upstream section of core duct 140, or more specifically, to core inlet 141. Core air A5 flows through core duct 140 (as described above) to generate combustion gases A7 and exits core duct 140 through core air exhaust nozzle 143 to generate core airflow, also referred to as second thrust flow S2.

[0052] Secondary bypass air A4 is directed or directed into fan duct 181 and enters fan duct 181 through fan duct inlet 183. The secondary bypass air A4 flows through fan duct 181 generally in the axial direction A and exits fan duct 181 through fan duct inlet 183 to generate a third flow, also referred to as the third thrust flow S3. The third thrust flow S3 is a secondary airflow that increases fluid energy to generate a small fraction of the total propulsion system thrust. In some embodiments, the pressure ratio of the third flow is higher than that of the primary propulsion flow (e.g., bypass or propeller-driven propulsion flow). Thrust can be generated by a dedicated nozzle or by mixing the secondary airflow with the primary propulsion flow or core airflow, for example, into a general nozzle. In some embodiments, the operating temperature of the secondary airflow is lower than the engine's maximum compressor discharge temperature. Furthermore, in some embodiments, aspects of the third flow (e.g., airflow characteristics, mixing characteristics, or exhaust characteristics), and thus the percentage contribution to total thrust, are passively adjusted during engine operation, or can be purposefully modified using engine control features (e.g., fuel flow, motor power, variable stator, variable inlet guide vanes, valves, variable exhaust geometry, or fluid characteristics) to adjust or improve overall system performance over a wide range of potential operating conditions.

[0053] The discussion here Figure 1The turbine engine 100 shown (e.g., a ductless fan engine) is provided by way of example only. In other embodiments, any other suitable engine may be used for various aspects of this disclosure. For example, in other embodiments, the engine may be any other suitable gas turbine engine, such as a high-bypass turbofan engine, a turboshaft engine, a turboprop engine, a turbojet engine, etc. In this way, in other embodiments, the gas turbine engine may have other suitable configurations, such as other suitable numbers or arrangements of shafts, compressors, turbines, fans, etc. Further, although the turbine engine 100 is shown as a geared variable-pitch turbofan engine, in other embodiments, the turbine engine 100 may be a direct-drive turbine engine or a fixed-pitch turbine engine. In other embodiments, the main fan 150 and the fan guide vane array 170 may be ducted or covered, including a nacelle or shield that circumferentially surrounds one or both of the main fan 150 and the fan guide vane array 170, either jointly or individually.

[0054] The turbine engine 100 discussed herein is suitable for use in aircraft. Suitable aircraft include, for example, airplanes and unmanned aerial vehicles (UAVs). In other embodiments, the turbine engine can be any other turbine engine, such as an industrial turbine engine incorporated into a power generation system, or a marine turbine engine used on ships or other vessels.

[0055] Figure 2A This is a cross-sectional view of a portion of the inlet duct 187, including the intermediate fan blades 192 and the integral frame 200, showing... Figure 1 Detail 2A. As described above, the fan shroud 174 partially defines the inlet duct 187 and circumferentially surrounds the central fan blade 192. More specifically, the fan shroud 174 may include one or more housings or housing segments to define the inlet duct 187. The integral frame 200 includes a frame housing 220, which is one of the housings defining the inlet duct 187. Another housing, referred to herein as a guide housing 230, is connected to the frame housing 220, for example, directly. Figure 2A The guide housing 230 shown is a downstream housing positioned downstream of the frame housing 220 relative to the flow of engine air A3 through the inlet pipe 187. Additional details regarding the connection between the frame housing 220 and the guide housing 230 will be discussed below, and these features can be applied to the guide housing positioned upstream of the frame housing 220.

[0056] Similarly, the inner hub housing 105 may include one or more housings or housing segments positioned opposite a housing segment of the fan shroud 174 to define an inlet duct 187 therebetween. The integral frame 200 further includes an inner hub 240, which is one of the housings defining the inlet duct 187. Figure 2A In this context, another type of inner housing, referred to herein as inner impeller housing 252, is disposed adjacent to and can be connected to the inner hub 240. Figure 2A In this configuration, the inner impeller housing 252 is a downstream housing disposed downstream of the inner hub 240 relative to the flow of engine air A3 through the inlet duct 187. An outer belt portion 222 is opposite the inner hub 240 to form an airflow path therebetween, such as a portion of the inlet duct 187. Both the frame housing 220, including the outer belt portion 222, and the inner hub 240 extend circumferentially about a frame centerline axis, which is parallel to the longitudinal centerline axis 101 of the turbine engine 100. Figure 1 ) consistent and along the axial direction A ( Figure 1 Each strut 210 connects the inner hub 240 to the outer belt portion 222 and extends between the outer belt portion 222 and the inner hub 240. The struts 210 are circumferentially spaced from each other about the centerline axis of the frame. The struts 210 may be hollow, and one or more of the struts 210 may have channels (not labeled) for service lines (e.g., wiring harnesses and fluid conduits) to extend from the nacelle fan shroud 174 ( Figure 1 It passes through the support column 210 and enters the fan section 102, the inner hub housing 105, the core cover 106, or any combination thereof.

[0057] Each support 210 may include a leading edge 211 formed on a front portion 212 of the support 210 and a trailing edge 213 formed on a rear portion 214 of the support 210. The support 210 includes a first wall 216 and a second wall (not shown), each connecting the front portion 212 and the rear portion 214. The second wall is positioned opposite the first wall 216 to form the outer axial side of the support 210. As described above, the support 210 may be hollow, and a cavity 218 may be defined between the first wall 216 and the second wall, and between the front portion 212 and the rear portion 214.

[0058] Figure 2A A portion of the inlet conduit 187 shown also includes a rotating airfoil assembly 260, which comprises a plurality of rotating airfoils 262 capable of rotating together about a rotation axis. Figure 2A The rotating airfoil assembly 260 shown is the intermediate fan 190, wherein the rotating airfoil 262 is the intermediate fan blade 192. The following discussion will refer to the intermediate fan 190, but the integral frame 200 can be used within the turbine engine 100. Figure 1Other locations of the intermediate fan 190 and its use with other rotating airfoil components 260 besides the intermediate fan 190. The intermediate fan 190 can be positioned upstream or downstream of the integral frame 200. Figure 2A As shown, for example, the intermediate fan blade 192 of the intermediate fan 190 is located in the inlet duct 187, downstream of the strut 210 of the integral frame 200 relative to the flow of engine air A3. The rotating airfoil assembly 260 includes a disk 264, such as disk 194, and disk 264 or a portion thereof may also partially define the inlet duct 187.

[0059] As described above, the frame housing 220 includes a receiving portion 224. The receiving portion 224 is disposed radially outward of the intermediate fan blade 192 and extends axially over the intermediate fan blade 192. The receiving portion 224 is positioned opposite the intermediate fan blade 192 and defines an inlet conduit 187 therebetween. The receiving portion 224 may be a fan housing. The receiving portion 224 may be part of a blade receiving system for retaining a broken blade or blade fragment therein.

[0060] The monolithic frame 200 can be formed from composite materials such as PMC, and can be a composite frame. The monolithic frame 200 may include a matrix 270 and multiple reinforcing fiber bundles 272 embedded in the matrix 270. For clarity, Figure 2A Only a portion of the reinforcing fiber bundle 272 is shown schematically, and any portion described herein may include the matrix 270 and the reinforcing fiber bundle 272 as arranged herein. When the composite material is a PMC material, the matrix 270 is a polymer, and the reinforcing fiber bundle 272 may be formed from one or more of the various reinforcing fiber bundles discussed above, such as carbon fibers.

[0061] The reinforcing fiber bundle 272 may, for example, be included in the turbine engine 100 ( Figure 1 The turbine engine 100 comprises a plurality of circumferential reinforcing fiber bundles 274 extending in the circumferential direction C and a plurality of axial reinforcing fiber bundles 276 extending in the axial direction A. Various suitable lamination techniques, including winding the reinforcing fiber bundles 272 around a mandrel and using one or more woven fabrics, can be used to laminate the reinforcing fiber bundles 272 to form a preform. When using woven fabrics, the circumferential reinforcing fiber bundles 274 and the axial reinforcing fiber bundles 276 are interwoven. Suitable woven fabrics include two-dimensional (2D) woven fabrics and three-dimensional (3D) woven fabrics. When using 3D woven fabrics, the reinforcing fiber bundles 272 may include interlocking reinforcing fiber bundles (not shown) to interlock multiple layers of reinforcing fiber bundles 272 together.

[0062] The housing portion 224 surrounds the intermediate fan 190, and the circumferential reinforcing fiber bundle 274 extends around the intermediate fan 190 in the circumferential direction C. When the circumferential reinforcing fiber bundle 274 is formed of carbon fiber or other similar fibers, the circumferential reinforcing fiber bundle 274 provides strength, especially impact strength, to the housing portion 224, allowing the fan housing portion 224 to act as a containment barrier for the blade containment system to retain broken blades or blade fragments and prevent these broken blades or blade fragments from being discharged through the housing portion 224.

[0063] like Figure 2A As shown, the outer casing 222 and the receiving portion 224 are integrally formed, and the frame housing 220 is a one-piece housing. The frame housing 220 can be a single-piece housing. Although the support column 210, the inner hub 240, or both can be separate components fastened to the frame housing 220, the support column 210 and the inner hub 240 are... Figure 2A The inner hub 240 is depicted as being integrally formed with the frame housing 220, for example, integrally formed with the outer belt portion 222 and the receiving portion 224. The strut 210, the inner hub 240, or both can be part of an integral frame having the outer belt portion 222 and the receiving portion 224.

[0064] The receiving portion 224 can extend in the axial direction A away from the outer portion 222 to the position described above. As described above, with this structure, joints can be omitted from adjacent shell sections, thereby reducing the weight and complexity of the shell structure. For example, the matrix 270 can be continuous. Similarly, axially reinforcing fiber bundles 276 can extend between adjacent sections of the frame shell 220. Figure 2A As shown, axially reinforcing fiber bundles 276 extend from the outer belt portion 222 and into the receiving portion 224, thereby providing continuous strength in the axial direction A. Therefore, the outer belt portion 222 and the receiving portion 224 can be an integral composite, and the frame housing 220 can also be an integral composite. Similarly, the strut 210, the inner hub 240, or both can be integrally formed with the frame housing, for example, integrally formed with the outer belt portion 222 and the receiving portion 224. The strut 210, the inner hub 240, or both can be part of an integral composite having the outer belt portion 222 and the receiving portion 224.

[0065] The integral frame 200 is not limited to composite materials and can be formed using other materials, such as metals suitable for use in aircraft environments. The frame shell 220 can be made of materials suitable for high-temperature environments (e.g., temperatures above 600°F), including corrosion-resistant alloys of stainless steel, nickel, and chromium, as well as high-strength nickel-based alloys. The frame shell 220 can be formed of metal alloys. Metal alloys can be iron-based, nickel-based, cobalt-based, chromium-based, or titanium-based alloys. The frame shell 220 can be made of materials suitable for use in low-temperature environments (e.g., temperatures below 400°F), including the aforementioned metal alloys as well as aluminum-based alloys. Various forming and molding techniques can be used to form the integral frame 200, including its integral or monolithic structure, including, for example, additive manufacturing techniques.

[0066] The integral frame 200 may include acoustic panels. These acoustic panels can be used and connected to housings discussed herein, such as frame housing 220 and inner hub 240. Frame housing 220 may include an outer acoustic panel 228 located inside frame housing 220. Similarly, inner hub 240 may include an inner acoustic panel 242 located outside frame housing 220. The outer acoustic panel 228, inner acoustic panel 242, or both may be integrally formed with frame housing 220 or inner hub 240, for example, by positioning during lamination or in another step of arranging prefabricated components when forming integral frame 200.

[0067] In addition to the strut 210, the turbine engine 100 may include multiple blades 250. Figure 2A In this configuration, blade 250 is the inlet blade of the rotating airfoil assembly 260 and is located upstream of the rotating airfoil assembly 260. More specifically, Figure 2A The blade 250 shown is an inlet intermediate fan blade 196 located upstream of the intermediate fan 190, for example, located in the inlet duct 187 upstream of the intermediate fan blade 192. The blade 250 can be arranged together with the inlet intermediate fan blade 196 in the manner described above, and this discussion can be applied to the turbine engine 100. Figure 1 Other locations within the ) . Multiple blades 250 are positioned downstream of multiple supports 210 relative to the direction of engine air A3 through inlet duct 187.

[0068] Blade 250 can be a static airfoil that cannot rotate about the longitudinal centerline axis 101. Although blade 250 can be a fixed-pitch blade, it can also be a variable-pitch blade, such as... Figure 2AAs shown. For example, each blade 250 is rotatable about a pitch axis relative to the blade housing portion 226. More specifically, the blade 250 may include a blade shaft 254 that supports the blade 250 and is connected to the blade housing portion 226 via, for example, a pivot bearing 256 that allows the blade 250 to rotate. A blade actuation system similar to the fan-guided blade actuation system 166 described above can be used to change the pitch of the blade 250 and rotate the blade shaft 254. The blade actuation system for the blade 250 can operate similarly to the fan-guided blade actuation system 166 discussed above, and this discussion applies here.

[0069] The blade housing portion 226 is positioned opposite the inner blade housing 252 to define a portion therebetween inlet conduit 187. Each blade 250 may extend radially from the inner blade housing 252 to the blade housing portion 226. The blade housing portion 226 is disposed radially outside the plurality of blades 250 and extends axially over the plurality of blades 250. Figure 2A In the arrangement shown, the impeller housing portion 226 is disposed between the outer belt portion 222 and the receiving portion 224. The impeller housing portion 226 may extend from the outer belt portion 222 and may extend from the receiving portion 224. The impeller housing portion 226 may be integrally formed with the outer belt portion 222, the receiving portion 224, or both, for example, by becoming part of an integral composite having the outer belt portion 222, the receiving portion 224, or both. Figure 2A In this configuration, the impeller housing portion 226 extends from the outer belt portion 222 to the receiving portion 224. The impeller housing portion 226 is also part of the same integral composite having the outer belt portion 222 and the receiving portion 224, for example, wherein axially reinforcing fiber bundles 276 extend from the outer belt portion 222, pass through the impeller housing portion 226, and enter the receiving portion 224, thereby providing continuous strength in the axial direction A. Similarly, the matrix 270 of the impeller housing portion 226 is continuous with both the outer belt portion 222 and the receiving portion 224.

[0070] As described above, fan cover 174 ( Figure 1 The system may also include a guide housing 230, which may also define an inlet conduit 187. The guide housing 230 may be connected to the frame housing 220, for example, directly. More specifically, the guide housing 230 may be disposed adjacent to the frame housing 220. Figure 2AIn this configuration, guide housing 230 defines a portion of the inlet pipe 187 downstream of frame housing 220 and is positioned downstream of the integral frame 200. Guide housing 230 may abut against frame housing 220. More specifically, frame housing 220 may include frame housing flange 282, and guide housing 230 may include guide housing flange 232. Each of frame housing flange 282 and guide housing flange 232 may project radially outward from frame housing 220 and guide housing 230, respectively. Figure 2A In the arrangement shown, the frame housing flange 282 is connected to, for example, formed as part of, the receiving portion 224. The frame housing flange 282 and the guide housing flange 232 can be configured to abut against each other, for example, the outwardly facing surfaces of each of the frame housing flange 282 and the guide housing flange 232 abut against each other. The guide housing 230 can be connected to the frame housing 220, for example, by fastening to the frame housing 220. For example, the frame housing 220 can be fastened to the guide housing 230 by a fastener 290 that engages with both the frame housing flange 282 and the guide housing flange 232. Holes may be formed in the frame housing flange 282, the guide housing flange 232, or both, for inserting the fastener 290. Although at least one of the frame housing flange 282 or the guide housing flange 232 is machined with internal threads, Figure 2A The fastener 290 shown is a bolt with a nut to fasten the guide housing flange 232 to the frame housing flange 282.

[0071] Figure 2B From similar Figure 1 A cross-sectional view of a portion of a turbine engine taken from the perspective of detail 2A. Figure 2B This is shown in conjunction with the above. Figure 2A The monolithic frame 200 discussed is similar to the monolithic frame 202. For the same or similar components of the monolithic frame 202, the same reference numerals as those used for the monolithic frame 200 discussed above are used, and this discussion applies here. In addition to the above combinations Figure 2A Beyond those discussed, the holistic framework can have various arrangements. Figure 2B For example, the rotating airfoil assembly 260 is positioned upstream of the plurality of struts 210 relative to the direction of engine air A3 via the inlet duct 187. The receiving portion 224 may be directly connected to the outer belt portion 222 and extends upstream from the outer belt portion 222 to be axially positioned on the rotating airfoil 262 of the rotating airfoil assembly 260.

[0072] exist Figure 2B In the middle, multiple blades 250 and above reference Figure 2AThe manner discussed is similar to that of the multiple struts 210 downstream, however, with the airfoil assembly 260 positioned upstream of the struts 210, each of the multiple blades 250 is an outlet blade of the airfoil assembly 260 and is positioned downstream of the airfoil assembly 260 relative to the flow of engine air A3 through the inlet duct 187.

[0073] The guide housing 230 and the frame housing 220 can be connected together in a variety of different ways, and include Figure 2A and 2B Other joints shown are not included. For example, one type of joint that can be used is one where a portion of the guide housing 230 and the frame housing 220 overlap each other. The overlapping joint shown here is called a lap joint. Figures 3 to 5 Different lap joint configurations for connecting the guide housing 230 to the frame housing 220 are shown. The same reference numerals will be used for... Figures 3 to 5 Each of the same or similar components in the figures, and the discussion in one figure applies to the discussion in other figures. Similarly, although described as separate joints, the features of one lap joint can be incorporated into another lap joint. Likewise, Figure 2A and 2B The fastener arrangement shown can be used for any lap joint discussed below. This discussion of lap joints concerns... Figure 2A The arrangement shown is carried out, and the lap joint is formed as part of the blade housing portion 226, extending axially over the rotating airfoil assembly 260. Therefore, the lap joint can be part of the housing structure of the rotating airfoil assembly 260, and the guide housing 230 can serve as part of the housing structure. However, lap joints can be formed in other portions of the frame housing 220. As mentioned above, the integral frame 200 and frame housing 220 can be composite materials. The guide housing 230 can be formed from different materials, such as metals suitable for aircraft use. In this case, the lap joint discussed herein can be a suitable joint for these different materials.

[0074] Figure 3 This is a cross-sectional view of the lap joint 300 of the integral frame 204, used to connect the frame housing 220 and the guide housing 230. The frame housing 220 includes a frame housing lip 310, and the guide housing 230 includes a guide housing lip 320. The frame housing lip 310 and the guide housing lip 320 are arranged or configured to overlap each other and form the lap joint 300. More specifically, in Figure 3In the arrangement shown, the frame housing lip 310 is disposed radially outside the guide housing lip 320. The frame housing lip 310 may be formed in the receiving portion 224, and the lap joint 300 extends axially over the rotating airfoil assembly 260. Thus, the guide housing 230 can be used to form part of the receiving structure for the rotating airfoil assembly 260.

[0075] The frame housing 220 may include a distal end 312 of the frame housing remote from the plurality of struts 210. A frame housing flange 282 may be formed on the distal end 312 of the frame housing. A guide housing flange 232 may be formed at any location on the guide housing lip 320 to provide a desired number of overlaps of the lap joints 300, such as a desired number of overlaps of the rotary airfoil assembly 260. The guide housing flange 232 may be located downstream of the rotary airfoil assembly 260, for example, as... Figure 3 As shown. The frame housing flange 282 and the guide housing flange 232 can be positioned to abut against each other, as described above. The frame housing lip 310 and the guide housing lip 320 can also be configured to abut against each other, for example, the bottom surface of the frame housing lip 310 abuts against the upper surface of the guide housing lip 320.

[0076] The frame housing lip 310 can be fastened to the guide housing lip 320. For example... Figure 3 As shown, for example, the frame housing 220 is fastened to the guide housing 230 in the lap joint 300 using one or more fasteners 290, which engage with both the frame housing lip 310 and the guide housing lip 320. Here, two fasteners 290 are shown extending through the integral frame housing lip 310 and into the guide housing lip 320.

[0077] Each rotating airfoil 262 may include a rotating airfoil tip 266. The rotating airfoil tip 266 may be tapered, such as... Figure 3 As shown. According to Figure 3 The arrangement of the frame housing lip 310 and guide housing lip 320 is shown, with the guide housing lip 320 positioned adjacent to the rotating airfoil 262, for example, adjacent to the tip 266 of the rotating airfoil. The guide housing lip 320 may include a guide housing inner surface 322 facing the rotating airfoil assembly 260. When the tip 266 of the rotating airfoil is tapered, the guide housing inner surface 322 may be tapered to correspond to the tapering of the tip 266 of the rotating airfoil.

[0078] Figure 4This is a cross-sectional view of another lap joint 302 for the integral frame 206, used to connect the frame housing 220 to the guide housing 230. The guide housing flange 232 includes a distal flange end 234. A flange protrusion 236 extends from the guide housing flange 232. The flange protrusion 236 extends in a direction from the distal flange end 234 toward the frame housing 220. The flange protrusion 236 can at least partially overlap with the guide housing lip 320. Thus, the flange protrusion 236 can form a channel with the guide housing lip 320. The frame housing lip 310 and the guide housing lip 320 overlap each other to form the lap joint 302, wherein the frame housing lip 310 is disposed between the guide housing lip 320 and the flange protrusion 236, for example within the channel, to connect the frame housing 220 to the guide housing 230.

[0079] The guide housing lip 320 includes a guide housing tip 324. Figure 4 The guide housing tip 324 shown is a stepped tip, and the frame housing lip 310 includes a step 314. The stepped tip (guide housing tip 324) engages with the step 314 of the frame housing 220 to further secure the guide housing 230 to the frame housing 220. Although Figure 4 Not shown in the image, but fastener 290 (see...) Figure 2A or Figure 3 It can also be used with the lap joint 302 construction.

[0080] Figure 5 This is a cross-sectional view of another lap joint 304 for the integral frame 208, used to connect the frame housing 220 to the guide housing 230. A soundboard can be used and connected to the housing discussed herein, such as the frame housing 220. Figure 5 The lap joint 304 also includes a sound plate, referred to herein as lap sound plate 330. The lap sound plate 330 is located radially inside the frame housing lip 310, the guide housing lip 320, or both.

[0081] The integral frames 200 and 202 discussed herein include integral shells (e.g., frame shell 220). Frame shell 220 can be formed into an integral composite from composite materials. Composite materials not only reduce the weight of the frame, but the integral assembly also reduces complexity, the number of joints, and the weight corresponding to these joints. The composite materials used herein are capable of forming such integral frames. Various connections between the integral composite shell 220 and adjacent shell structures, such as guide shell 230, are also disclosed herein. Joints, such as lap joints 300, 302, and 304, can provide good joint structures, especially when using different materials, and can also be positioned to provide a combined receiving structure for the rotating airfoil assembly 260.

[0082] Further aspects of this disclosure are provided by the subject matter of the following clauses.

[0083] A turbine engine for an aircraft has axial and radial directions. The turbine engine includes a rotating airfoil assembly and an integral frame. The rotating airfoil assembly includes a plurality of rotating airfoils rotatable about a common axis of rotation. The integral frame includes: an inner hub; a frame housing having an outer band portion and a receiving portion integrally formed with the outer band portion; and a plurality of struts connecting the inner hub to the outer band portion. The outer band portion is opposite to the inner hub to form an airflow path therebetween. The receiving portion extends axially away from the outer band portion. The receiving portion is positioned radially outward of the plurality of rotating airfoils and extends axially over the plurality of rotating airfoils. Each of the plurality of struts extends radially and is positioned within the airflow path.

[0084] According to the turbine engine described in the foregoing clause, the rotating airfoil assembly is positioned upstream of the plurality of struts relative to the direction of the airflow through the airflow path.

[0085] According to any of the preceding clauses, the turbine engine wherein the rotating airfoil assembly is positioned downstream of the plurality of struts relative to the direction of the airflow through the airflow path.

[0086] According to any of the foregoing clauses, the inner hub and the plurality of struts are integrally formed with the outer belt portion and the housing portion.

[0087] The turbine engine according to any of the foregoing clauses further includes a plurality of wheel blades.

[0088] According to the turbine engine described in the foregoing clause, the integral frame further includes a blade housing portion disposed radially outside the plurality of blades and extending axially over the plurality of blades, the blade housing portion being integrally formed with the outer belt portion and the receiving portion.

[0089] The turbine engine according to any of the foregoing clauses, wherein each of the plurality of blades is the exit blade of the rotating airfoil assembly.

[0090] The turbine engine according to any of the foregoing clauses, wherein each of the plurality of blades is the inlet blade of the rotating airfoil assembly.

[0091] According to any of the foregoing clauses, the plurality of blades are positioned downstream of the plurality of struts relative to the direction of airflow through the airflow path.

[0092] According to any of the foregoing clauses, the rotating airfoil assembly is positioned upstream of the plurality of struts relative to the direction of the airflow through the airflow path.

[0093] According to any of the preceding clauses, the turbine engine wherein the rotating airfoil assembly is positioned downstream of the plurality of struts relative to the direction of the airflow through the airflow path.

[0094] In any of the preceding clauses of the turbine engine, the blade housing portion is disposed between the outer belt portion and the housing portion.

[0095] The turbine engine according to any of the foregoing clauses further includes a guide housing that defines a portion of the airflow path, the guide housing being positioned adjacent to and secured to the frame housing.

[0096] The turbine engine according to any of the foregoing clauses, wherein the frame housing includes a frame housing flange.

[0097] The turbine engine according to any of the foregoing clauses, wherein the guide housing includes a guide housing flange.

[0098] According to any of the foregoing clauses, the guide housing flange abuts against the frame housing flange.

[0099] According to any of the preceding clauses, the turbine engine wherein the frame housing is fastened to the guide housing by fasteners that engage with both the frame housing flange and the guide housing flange.

[0100] The turbine engine according to any of the foregoing clauses, wherein the frame housing includes a frame housing distal end remote from the plurality of struts, the frame housing flange being formed on the frame housing distal end.

[0101] The turbine engine according to any of the foregoing clauses, wherein the guide housing includes a guide housing lip.

[0102] The turbine engine according to any of the foregoing clauses, wherein the frame housing includes a frame housing lip.

[0103] According to any of the foregoing clauses, the guide housing lip overlaps the frame housing lip to form a joint.

[0104] The turbine engine according to any of the foregoing clauses, wherein the joint is a lap joint.

[0105] According to any of the preceding clauses, the turbine engine, wherein the guide housing flange includes a flange distal end and a flange protrusion extending from the flange distal end.

[0106] According to any of the preceding clauses, the guide housing lip overlaps the frame housing lip to form a joint with the frame housing lip disposed between the guide housing lip and the flange protrusion.

[0107] The turbine engine according to any of the foregoing clauses, wherein the guide housing lip includes a tip, the tip being a stepped tip.

[0108] According to any of the foregoing clauses, the turbine engine wherein the frame housing lip includes a step, and the stepped tip of the guide housing lip engages with the step of the frame housing.

[0109] According to any of the preceding clauses, the turbine engine wherein the frame housing is fastened to the guide housing in the joint by fasteners, the fasteners engaging with both the lip of the frame housing and the lip of the guide housing.

[0110] According to any of the foregoing clauses, the turbine engine wherein the frame housing lip is formed in the receiving portion and the joint extends axially over the rotating airfoil assembly.

[0111] The turbine engine according to any of the foregoing clauses, wherein the joint includes a sound plate.

[0112] The turbine engine according to any of the foregoing clauses, wherein the frame housing lip is disposed radially outside the guide housing lip.

[0113] According to any of the preceding clauses, each of the plurality of rotating airfoils is tapered in the axial direction.

[0114] According to any of the preceding clauses, the turbine engine wherein the guide housing lip has a lower side that is tapered to correspond to the tapering of each of the plurality of rotating airfoils.

[0115] While the above description is directed to certain embodiments, other variations and modifications will be apparent to those skilled in the art and can be made without departing from this disclosure. Furthermore, features described in connection with one embodiment can be used in conjunction with other embodiments, even if not explicitly stated above.

Claims

1. A turbine engine for an aircraft, the turbine engine having an axial direction and a radial direction, characterized in that, The turbine engine includes: A rotating airfoil assembly, the rotating airfoil assembly comprising a plurality of rotating airfoils capable of rotating together about a rotation axis; and An integral frame, the integral frame comprising: Inner hub; A frame housing having an outer band portion and a receiving portion integrally formed with the outer band portion, the outer band portion opposing the inner hub to form an airflow path therebetween, the receiving portion extending axially away from the outer band portion and positioned radially outward of the plurality of rotating airfoils and extending axially above the plurality of rotating airfoils; and Multiple struts connect the inner hub to the outer belt portion, each of the multiple struts extending in the radial direction and positioned within the airflow path.

2. The turbine engine according to claim 1, characterized in that, The rotating airfoil assembly is positioned upstream of the plurality of struts relative to the direction of the airflow through the airflow path.

3. The turbine engine according to claim 1, characterized in that, The rotating airfoil assembly is positioned downstream of the plurality of struts relative to the direction of the airflow through the airflow path.

4. The turbine engine according to claim 1, characterized in that, The assembly further includes a plurality of blades, each of which is an outlet blade of the rotating airfoil assembly, the blades being positioned downstream of the plurality of struts relative to the direction of the airflow through the airflow path. The integral frame further includes a blade housing portion disposed radially outside the plurality of blades and extending axially over the plurality of blades, the blade housing portion being integrally formed with the outer belt portion and the receiving portion, and The rotating airfoil assembly is positioned upstream of the plurality of struts relative to the direction of the airflow through the airflow path.

5. The turbine engine according to claim 1, characterized in that, The system further includes multiple blades, wherein the integral frame further includes a blade housing portion disposed radially outside the multiple blades and extending axially over the multiple blades, the blade housing portion being integrally formed with the outer belt portion and the receiving portion, and... The impeller housing portion is disposed between the outer belt portion and the receiving portion.

6. The turbine engine according to claim 5, characterized in that, The rotating airfoil assembly is positioned downstream of the plurality of struts relative to the direction of the airflow through the airflow path, and Each of the plurality of blades is the inlet blade of the rotating airfoil assembly.

7. The turbine engine according to claim 1, characterized in that, The outer portion and the receiving portion are an integral composite having multiple reinforcing fibers embedded in a matrix.

8. The turbine engine according to claim 7, characterized in that, The inner hub and the plurality of struts are part of the integral composite having the outer belt portion and the receiving portion.

9. The turbine engine according to claim 7, characterized in that, The assembly further includes a plurality of blades, wherein the integral frame further includes a blade housing portion disposed radially outside the plurality of blades and extending axially over the plurality of blades, the blade housing portion being part of the integral composite having the outer belt portion and the receiving portion.

10. The turbine engine according to claim 1, characterized in that, It further includes a guide housing that defines a portion of the airflow path and is positioned adjacent to and secured to the frame housing.

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