Airfoil assembly for an engine having a composite spar

Abstract

An airfoil assembly for an engine has an airfoil body, a composite spar, a sleeve assembly, and a set of paddles. The composite spar has an inner spar portion located inside the airfoil body and an outer spar portion located outside the airfoil body. The sleeve assembly includes an outer sleeve and an inner sleeve. The set of paddles can extend from the inner sleeve or the outer sleeve toward the other of the inner sleeve or the outer sleeve.

Description

Technical Field

[0001] This disclosure generally relates to airfoil assemblies, and more specifically, to airfoil assemblies having sleeve assemblies and composite 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 impellers), through a combustor, and then through a series of turbine stages (which also consist of pairs of rotating blades and stationary impellers) into the engine. The blades are mounted to a rotating disk, while the impellers 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 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.

[0004] In some engines, a variable-pitch airfoil may be included, which can be selectively rotated to adjust or otherwise customize the fluid flow on the variable-pitch airfoil. The variable-pitch airfoil can be moved using a sleeve and a sparsity. The sleeve may have a direction of rotation about the pitch axis, which in turn causes the sparsity and the variable-pitch airfoil to rotate. The sleeve is attached to the sparsity or otherwise formed together with the sparsity. Attached Figure Description

[0005] The complete and practical disclosure of this disclosure, including its best mode, is set forth in the description with reference to the accompanying drawings, for those skilled in the art, wherein:

[0006] Figure 1 This is a schematic cross-sectional view of a non-pipeline or open rotor turbine engine.

[0007] Figure 2 It includes Figure 1 A schematic perspective view of an aircraft with a non-pipeline or open rotor turbine engine.

[0008] Figure 3 This is an exemplary embodiment of the present disclosure, including a composite spar and a sleeve assembly. Figure 2Side view of the airfoil component assembly.

[0009] Figure 4 Based on the various aspects described in this article Figure 3 The schematic cross-sectional view of the airfoil assembly seen along section line IV-IV further illustrates an exemplary construction of the sleeve and composite spar.

[0010] Figure 5 Based on the various aspects described in this article Figure 3 The schematic cross-sectional view of the airfoil assembly seen by section line VV further illustrates the exemplary construction of the sleeve and composite spar.

[0011] Figure 6 This illustrates the formation of the various aspects described herein. Figure 3 A flowchart illustrating an exemplary method for an airfoil component assembly.

[0012] Figure 7 Based on the various aspects described in this article Figure 4 A variation of the schematic cross-sectional view of the airfoil component assembly.

[0013] Figure 8 Based on the various aspects described in this article Figure 7 A schematic cross-sectional view of the airfoil assembly as seen from section lines VIII-VIII.

[0014] Figure 9 Based on the various aspects described in this article Figure 8 A variation of the airfoil component assembly. Detailed Implementation

[0015] The aspects and advantages of this disclosure will be set forth in part in the description which follows, or may be apparent from the description, or may be learned by practicing the disclosure herein.

[0016] Traditionally, airfoil components include metal spars that are formed together with or attached to a metal sleeve.

[0017] The aspects disclosed herein relate to airfoil assemblies for engines. Non-limiting examples of engines may include electric motors, turbine engines, or hybrid engines. Although shown as turbine engines, it will be understood that other engines and propulsion systems may also be used. Thus, for example, the aspects disclosed herein relate to airfoils for turbine engines having an airfoil body with a compound spars, a portion of which is received by a sleeve assembly. The metal sleeve assembly may include an inner sleeve and an outer sleeve, wherein the outer sleeve is spaced apart from and surrounds the inner sleeve. The compound spars are received at the radially outer surface of the inner sleeve. The compound spars may also be received at the radially inner surface of the outer sleeve. The sleeve assembly may further include a set of paddles extending from the inner or outer sleeve toward another of the inner or outer sleeves. This set of paddles is at least partially embedded in or located within the portion of the compound spars received by the sleeve assembly. This set of paddles transmits torque between the compound spars, the inner sleeve, the outer sleeve, or any combination thereof.

[0018] One or more of the paddles in this group can be coupled to an outer sleeve, an inner sleeve, or a combination thereof. Additionally or alternatively, one or more of the paddles in this group can be integrally formed with the outer sleeve or the inner sleeve. The group of paddles can be located within a set of spars recesses. That is, a portion of the composite spars can define a spars recess that receives one or more of the paddles in this group. The set of spars recesses can be formed during the laying of the composite spars or can be machined into the composite spars after curing or partial curing.

[0019] Mechanical interlocking between the paddles, the metal sleeve assembly, and the composite spar provides an improved connection between the composite spar and the metal sleeve assembly. This paddle assembly can also transfer torque applied to the airfoil body (e.g., changes in airfoil pitch, alterations in atmospheric flow, or impact events) to the inner sleeve, outer sleeve, or a combination thereof. This can extend the lifespan of the airfoil assembly.

[0020] The sleeve assembly can be cast, printed, or forged to have the set of recesses on the radial surface of the inner sleeve, outer sleeve, or a combination thereof. Alternatively, the set of recesses can be machined into the sleeve assembly.

[0021] This set of paddles can be formed together with or attached to a metal sleeve assembly. The airfoil body and the composite spar are formed of composite material. A portion of the uncured composite spar can be received by the sleeve assembly having this set of paddles. That is, a portion of the composite spar preform or a portion of a multi-piece composite spar can be located in the sleeve assembly before full curing. The uncured composite spar material forms the spar recess that receives the set of paddles. Upon curing, the composite spar shape solidifies. The set of paddles located within the spar recess provides an improved interface between the metal material of the sleeve assembly and the composite material of the spar.

[0022] Alternatively, in various and non-limiting examples, the composite spars can be cured or at least partially cured, such that the set of spars recesses can be machined into the composite spars. As used herein, the term "partially cured" can include curing the object to 40% curing, but less than 100% curing. In yet another various and non-limiting example, the composite spars can be assembled or consolidated into the set of paddles. The set of paddles can then be formed together with the sleeve assembly, or received by both the sleeve recess and the spars recess, to provide interlocking of the metallic material of the sleeve assembly and the composite material of the composite spars.

[0023] Reference will now be made in detail to the present embodiments of this disclosure, one or more examples of which are illustrated in the accompanying drawings. The detailed description uses numerals and letter reference numerals to denote features in the drawings. Similar or analogous reference numerals in the drawings and description have been used to denote similar or analogous portions of this disclosure.

[0024] As used herein, the term "composite material" refers to a material that does not contain metallic materials. A composite material can be a combination of at least two or more non-metallic elements or materials. Examples of composite materials can be, but are not limited to, polymer matrix composites (PMC), ceramic matrix composites (CMC), carbon fibers, polymeric resins, thermoplastics, bismaleimide (BMI), polyimide materials, epoxy resins, glass fibers, and silicon matrix materials.

[0025] As used herein, the term “metal composite” refers to a composite material bonded to a metal or metallic material, such as a metal matrix composite (MMC) or carbon fiber infused with metal fibers.

[0026] 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.

[0027] One or more adhesive layers may be used to form or join composite components. The adhesive may include resins and phenolic resins, where the adhesive may require curing at elevated temperatures or other hardening techniques.

[0028] 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.

[0029] 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.

[0030] 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 woven or braided 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.

[0031] 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, braided material, woven material, or any combination thereof.

[0032] 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.

[0033] 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 materials can be manual or automated.

[0034] 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.

[0035] 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.

[0036] 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.

[0037] 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, and so on. 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.

[0038] In some non-limiting examples, the reinforcing fibers may be bundled and / or coated before being incorporated into the ceramic 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.

[0039] 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 engine components used in the higher-temperature range of engines (such as airfoils (e.g., turbines and blades), combustors, shields, etc.) is currently being considered, as they would benefit from the lighter weight and higher-temperature capabilities these materials can offer.

[0040] As used herein, the terms "additive manufacturing" and "additive fabrication" generally refer to a manufacturing process in which consecutive layers of material are disposed on top of each other to build a three-dimensional part layer by layer or block by block. Consecutive blocks or layers are often fused together to form an integral part that can have a variety of integral components. The additive manufacturing processes described herein can be used to form parts using any suitable material. For example, the material can be plastic, metal, ceramic, polymer, epoxy, thermoplastic resin, or any other suitable material that can be solid, liquid, powder, sheet, wire, or any other suitable form. More specifically, according to exemplary embodiments of this disclosure, the additively manufactured parts described herein can be formed partially, wholly, or in some combination of materials, including but not limited to titanium, iron, aluminum, stainless steel, and nickel alloys.

[0041] 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. A metallic material or alloy can be a combination of at least two or more elements or materials, at least one of which is a metal. Other elements or materials can be nonmetals.

[0042] The term "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any implementation described herein as "exemplary" is not necessarily to be construed as superior or better than other implementations. Furthermore, unless explicitly stated otherwise, all embodiments described herein should be considered exemplary.

[0043] As used herein, the terms “first” and “second” are used interchangeably to distinguish one component from another and are not intended to indicate the location or importance of the individual components.

[0044] The terms "front" and "rear" refer to relative positions within an engine or vehicle, and to the normal operating posture of the engine or vehicle. For example, for a gas turbine engine, "front" refers to the position closer to the engine inlet, while "rear" refers to the position closer to the engine nozzle or exhaust port.

[0045] 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 "forward" or "front" indicate being in front of something, and "backward" or "rear" indicate being behind something. For example, when used in relation to fluid flow, forward / frontward can indicate upstream, while backward / rearward can indicate downstream.

[0046] The term "fluid" can refer to a gas or a liquid, or a multiphase system.

[0047] Furthermore, as used herein, the term "radial" or "radially" refers to a direction away from a 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.

[0048] 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 for identification purposes only to aid the reader's understanding of this disclosure and do not impose limitations, particularly regarding the location, orientation, or purpose of aspects of this disclosure described herein. Unless otherwise stated, connective references (e.g., attachment, connection, joint, and engagement) are to be interpreted broadly and may include intermediate structural elements between sets of elements as well as relative movement between elements. Therefore, a connective reference does not necessarily imply that two elements are directly connected and have a fixed relationship with each other. Exemplary drawings are for illustrative purposes only, and the dimensions, positions, order, and relative sizes reflected in the accompanying drawings may vary.

[0049] Unless the context clearly specifies otherwise, the singular forms “a,” “an,” and “the” include plural references. Furthermore, as used herein, the term “group” or a “group” of elements can be any number of elements, including only one.

[0050] "Optional" or "optionally" means that the event or situation described below may or may not occur, and the description includes instances where the event occurs and instances where the event does not occur.

[0051] Throughout this specification and claims, scope limitations are combined and interchanged, and unless the context or language otherwise indicates otherwise, such scopes are identified and include all subscopes contained herein. For example, all scopes disclosed herein include endpoints, and endpoints may be combined independently of each other.

[0052] In some exemplary embodiments of this disclosure, the non-ducted or open rotor turbine engine includes a set of circumferentially spaced fan blades extending externally beyond the nacelle surrounding the engine core.

[0053] Go to Figure 1A schematic cross-sectional view of an exemplary turbine engine 10 in the form of an open rotor or non-ducted fan engine for an aircraft is shown. 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 the following downstream serial flow arrangement: 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.

[0054] The external 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. As shown, the fan section 18 is positioned at the front of the nacelle 40 and also in front of the combustion section 28. It is conceivable that the fan section 18 may be positioned axially forward, rearward, or in a straight line with the combustion section 28. That is, a propulsion configuration is conceivable, in which one or more propulsion devices or sections are located axially rearward of the combustion section 28.

[0055] In the non-limiting example shown, fan section 18 includes circumferentially spaced blades or propellers defining a set of rotatable fan blades 42 (also referred to herein as "a set of fan blades 42") and circumferentially spaced stationary airfoils defining a set of fan impellers 82. The set of fan impellers 82 may be positioned downstream of the set of fan blades 42. The set of fan blades 42 and the set of fan impellers 82 are arranged radially from and circumferentially about the engine centerline 12. It is also contemplated that multiple sets of fan blades 42 or multiple sets of fan impellers 82 may be provided, for example, in an alternating arrangement, wherein in one example, the fan impellers are axially arranged between the fan blades. It is further contemplated that the set of fan impellers 82 may be rotatable such that the set of fan blades 42 rotates about the engine centerline 12 in a first direction and the set of fan impellers 82 rotates about the engine centerline 12 in a second direction.

[0056] The fan blades 42 can be mounted in various ways. One mounting method is to attach the blades to a central hub or disc, which can be driven by the engine's gearbox. In an exemplary embodiment, the airfoil assembly may include a dovetail tenon received in a complementary slot within the hub. In this way, any suitable number of composite airfoil assemblies can be mounted circumferentially around the hub to collectively form a rotating assembly.

[0057] 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.

[0058] 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 HP spool 48 and LP spool 50 are rotatable about the engine centerline 12 and are connected to a set of rotatable elements that together define a rotor 51.

[0059] It should be understood that the turbine engine 10 can be a direct drive or integral drive engine that utilizes a reduction gearbox that connects the LP shaft or spool 50 to the fan 20.

[0060] LP compressor 24 and HP compressor 26 each include a set of compressor stages 52 and 54, respectively, in which a set of compressor blades 56 and 58 rotate relative to a corresponding set of static compressor impeller blades 60 and 62 (also referred to as nozzles) to compress or pressurize the fluid flow passing through the stage. In a single compressor stage 52 or 54, multiple compressor blades 56 and 58 are arranged in a ring and extend radially outward from the blade platform relative to the engine centerline 12 to the blade tips, while the corresponding static compressor impeller blades 60 and 62 are positioned upstream of and adjacent to the compressor blades 56 and 58. It is worth noting that... Figure 1 The number of blades, impellers, and compressor stages shown is selected for illustrative purposes only, and other numbers are also possible.

[0061] 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 a corresponding 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.

[0062] HP turbine 34 and LP turbine 36 each comprise a set of turbine stages 64 and 66, respectively, in which a set of turbine blades 68 and 70 rotate relative to a corresponding set of static turbine blades 72 and 74 (also referred to as nozzles) to extract energy from the fluid flow passing through the stage. In a single turbine stage 64 and 66, multiple turbine blades 68 and 70 are arranged in a ring and extend radially outward from the blade platform relative to the engine centerline 12 to the blade tips, while the corresponding static turbine blades 72 and 74 are positioned upstream of and adjacent to the turbine blades 68 and 70. It is worth noting that... Figure 1 The number of blades, impellers, and turbine stages shown is selected for illustrative purposes only; other numbers are also possible.

[0063] 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.

[0064] The rotating parts of the turbine engine 10 (e.g., blades 56, 58, 68, 70 in the compressor section 22 and turbine section 32) are also referred to individually or collectively as rotor 51. Therefore, rotor 51 refers to the combination of rotating elements throughout the turbine engine 10.

[0065] Complementing the rotating parts, the stationary parts of the turbine engine 10 (e.g., the static blades 60, 62, 72, 74 in the compressor section 22 and the turbine section 32) are also referred to individually or collectively as the stator 63. Therefore, the stator 63 refers to the combination of non-rotating elements throughout the turbine engine 10.

[0066] Alternatively, rotor 51 may be a first rotor, and stationary portions of the turbine engine 10 (such as the static blades 60, 62, 72, 74 in the compressor section 22 and turbine section 32) may be coupled to a second rotor located radially outside the first rotor. The first and second rotors may rotate in opposite directions, thereby producing an engine rotating in opposite directions.

[0067] 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, exhaust section 38, or a combination thereof. The nacelle 40 may extend axially forward such that a portion of the nacelle 40 covers or conceals a portion of the fan section 18 or the supercharger section of the turbine engine 10.

[0068] During operation of the turbine engine 10, the working airflow 76 enters the engine core 44, and the inlet airflow 78 flows through the fan section 18 and the nacelle 40. The inlet airflow 78 flows over the set of fan blades 42, through at least a portion of the set of fan blades 82, and through the nacelle 40 of the turbine engine 10. Then, the inlet airflow 78 follows the curvature of the nacelle 40 and flows towards the exhaust section 38 through the set of fan blades 82. At least some of the inlet airflow 78 merges with the working airflow 76 downstream of the exhaust section 38 of the turbine engine 10. In this way, the working airflow 76 and the inlet airflow 78 together form the total thrust of the turbine engine 10.

[0069] The working airflow 76 can be used for combustion within the engine core 44. More specifically, the working airflow 76 flows into the LP compressor 24, which then pressurizes the working airflow 76, thereby defining a pressurized airflow supplied to the HP compressor 26, which further pressurizes the air. The working airflow 76 or pressurized airflow from the HP compressor 26 mixes with and ignites fuel in the combustor 30, thereby generating combustion gases. The HP turbine 34 extracts some work from these gases, which drives the HP compressor 26. The combustion gases are discharged into the LP turbine 36, which extracts additional work to drive the LP compressor 24, and the working airflow 76 or exhaust gas is ultimately 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.

[0070] A portion of the working airflow 76 can also be drawn as bleed air 77 (e.g., from compressor section 22). Bleed air 77 provides airflow to engine components for cooling. The temperature of the working airflow 76 leaving the combustor 30 is significantly increased relative to the working airflow 76 within compressor section 22. Therefore, the cooling provided by bleed air 77 can be used to operate 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 the combustion section 28.

[0071] Figure 2 It shows having Figure 1 An exemplary aircraft 80 with a turbine engine 10. The aircraft 80 can have any suitable form. As shown, the aircraft 80 includes a fuselage 98, from which wings 86 and a tail 88 extend.

[0072] A turbine engine 10 having an engine centerline 12 is shown as having the set of fan blades 42 and the set of fan rotor blades 82. The turbine engine 10 includes at least one airfoil assembly 100. In the non-limiting example shown, the airfoil assembly 100 is disposed in the set of fan blades 42. It should be understood that the airfoil assembly 100 may be disposed in any suitable part of the turbine engine 10, including the set of fan rotor blades 82, the set of static compressor rotor blades 60, 62, or the set of static turbine rotor blades 72, 74. Figure 1 In one of the turbine blades 56, 58 or 68, 70, the airfoil assembly 100 may be disposed from compressor blades 56, 58 or turbine blades 68, 70. Figure 1 In the leaves of ).

[0073] Figure 3 This is a schematic diagram illustrating an airfoil assembly 100 in an exemplary embodiment. As shown, the airfoil assembly 100 may include at least an airfoil body 110, a composite sparsity 120, and a sleeve assembly 130. As a non-limiting example, the airfoil body 110 may be a blade, a wheel blade, an airfoil, or any other component of an engine (such as, but not limited to, an electric motor, a hybrid motor, a gas turbine engine, a turboprop engine, a turboshaft engine, or a turbofan engine).

[0074] The airfoil body 110 includes a skin or outer wall 112 defining an interior 114. The outer wall 112 extends between a root 102 and a tip 104, defining the spanwise direction (Sd). The outer wall 112 also extends between a leading edge 106 and a trailing edge 108 to define the chordwise direction (Cd).

[0075] The composite spar 120 extends between the first spar end 122 and the second spar end 124. An inner spar portion 126 of the composite spar 120 is located within the interior 114 of the airfoil body 110. The inner spar portion 126 can be attached to the interior 114 by any suitable method, such as, but not limited to, bonding, fastening, or a combination thereof. An outer spar portion 128 of the composite spar 120 extends to the outside or exterior of the airfoil body 110. The outer spar portion 128 is received by a sleeve assembly 130. Although shown as having a space between the airfoil body 110 and the sleeve assembly 130, in various and non-limiting examples, it is contemplated that one or more portions of the airfoil body 110 may contact the composite spar 120.

[0076] Although schematically shown as a rectangle, the composite spar 120 may have a varying geometric profile between the first spar end 122 and the second spar end 124. For example, the composite spar 120 may have a first geometric profile at the first spar end 122 and transition to a second geometric profile at the second spar end 124. One or both of the first spar end 122 and the second spar end 124 may have a cylindrical, flared, convex, concave, square, asymmetrical, or irregular geometric profile.

[0077] The composite spar 120 may comprise a composite material or a metal composite material. As a non-limiting example, the composite spar 120 may comprise a polymer material, thermoplastic, polymer matrix composite (PMC), ceramic matrix composite (CMC), bismaleimide (BMI), polyimide, metal matrix composite (MMC), or carbon fiber infused with metal fibers. In some examples, the composite spar 120 may comprise interlaced or braided fibers, wherein the fibers may comprise single strands, fiber bundles, woven fibers, braided fibers, twisted fibers, knitted fibers, yarns, or combinations thereof arranged in a twist and subsequently braided to form the composite spar 120.

[0078] At least a portion of the outer spar portion 128 of the composite spar 120 is received within the hollow interior of the sleeve assembly 130. In some examples, the outer spar portion 128 may be held in place by frictional contact, engagement, adhesion, riveting, fasteners, wedges, paddles, or combinations thereof within the sleeve assembly 130.

[0079] In some examples, sleeve assembly 130 may include metallic materials such as, but not limited to, titanium, iron, aluminum, stainless steel, or nickel. Sleeve assembly 130 may be coupled to or mounted to a rotatable disk, hub, etc., and can therefore be used to mount airfoil assembly 100 to such a rotatable disk, hub, etc.

[0080] In some examples, the sleeve assembly 130 can be used to mount the airfoil assembly 100 in a variable pitch arrangement, wherein the airfoil assembly 100 can be at least partially moved or its pitch adjusted relative to the incoming airflow direction (e.g., parallel to the working airflow 76). Therefore, during operation of the airfoil assembly 100, the sleeve assembly 130 can rotate about the pitch axis (Pax) in the rotation direction (Rd). Since the composite spars 120 can connect the sleeve assembly 130 to the airfoil body 110, rotation of the sleeve assembly 130 about the rotation direction (Rd) can cause rotation of the airfoil body 110 about the pitch axis (Pax). Therefore, the airfoil body 110 can be a variable pitch airfoil in a variable pitch airfoil assembly.

[0081] In various and non-limiting examples, the sleeve assembly 130 can be used to mount the airfoil assembly 100 in a fixed arrangement, wherein the airfoil assembly 100 is stationary relative to rotation about the pitch axis (Pax).

[0082] In yet another different and non-limiting example, sleeve assembly 130 may be used to mount airfoil assembly 100 in a fixed arrangement such that the composite airfoil assembly forms a blade (e.g., a blade in the set of fan blades 82).

[0083] Optionally, the sleeve assembly 130 can be coupled to and communicate with a fan pitch actuation system (FPAS). The FPAS generally controls the pitch (e.g., angle, orientation) and rotation of the airfoil body 110 about the pitch axis (Pax), which can be used to improve efficiency and / or generate certain flow characteristics during operation of the airfoil assembly 100 (e.g., during flight).

[0084] Go to Figure 4 ,exist Figure 3 The schematic cross-section taken at line IV-IV shows the sleeve assembly 130 and the composite spar 120 according to an exemplary embodiment. The sleeve assembly 130 includes an outer sleeve 132 and an inner sleeve 134. The outer sleeve 132 has a radially outer surface 131 and a radially inner surface 133. The radially outer surface 131 may at least partially define the outermost surface of the sleeve assembly 130.

[0085] The sleeve centerline 142 can be centrally defined within the outer sleeve 132. In some examples, the sleeve centerline 142 can be aligned with the pitch axis (Pax). Figure 3 Collinear.

[0086] The inner sleeve 134 has a radially inner surface 135 and a radially outer surface 136. The inner sleeve 134 may be at least partially positioned within a portion of the hollow interior of the outer sleeve 132. The inner sleeve 134 may be spaced apart from the radially inner surface 133 of the outer sleeve 132. In other words, the outer sleeve 132 may surround the inner sleeve 134 such that the radially inner surface 133 of the outer sleeve 132 is spaced apart from the radially outer surface 136 of the inner sleeve 134 by a certain distance. The radially inner surface 133 of the outer sleeve 132 and the radially outer surface 136 of the inner sleeve 134 may partially define a hollow ring of the sleeve assembly 130 that receives the outer spar portion 128 ( Figure 3 At least a portion of the composite spar 120. That is, the outer spar portion 128 of the composite spar 120. Figure 3 At least a portion of the spar is received at the radially inner surface 133 of the outer sleeve 132. The spar thickness 144 can be measured perpendicularly to the sleeve centerline 142 from the radially outer surface 136 of the inner sleeve 134 to the radially inner surface 133 of the outer sleeve 132. It is important to note that in some examples discussed further in detail herein, the recess may exist on the radially inner surface 133, the radially outer surface 136, or a combination thereof. In this configuration, the spar thickness 144 is measured ignoring the recess.

[0087] The top portion 137 and the bottom portion 138 extend from the radial outer surface 131 of the outer sleeve 132 to the radial inner surface 133. The length 140 of the outer sleeve can be measured from the bottom portion 138 to the top portion 137.

[0088] The inner sleeve 134 may extend in the spanwise direction (Sd) between the first end 145 and the second end 146 to define an inner sleeve length 147. In some examples, the inner sleeve length 147 may be in the range of 30-60% of the outer sleeve length 140. The benefits of this range include, but are not limited to, increasing the cross-sectional area for transmitting torque loads and improving the ease of manufacturing and assembling the sleeve assembly 130.

[0089] Optionally, the spar core 170 may be coupled to the axial end 148 of the inner sleeve at the transition portion 149. The spar core 170 may be formed of a composite material or foam wrapped with a composite material. The transition portion 149 may include an adhesive for connecting the axial end 148 of the inner sleeve and the spar core 170.

[0090] The airfoil assembly 100 also includes a set of paddles 150 formed together with or located on the sleeve assembly 130 before a portion of the composite spars 120 is positioned within the sleeve assembly 130. The set of paddles 150 may comprise metallic materials such as, but not limited to, titanium, iron, aluminum, stainless steel, or nickel. In some examples, the set of paddles 150 may be formed integrally with the sleeve assembly 130 by machining the sleeve assembly 130 or by casting the sleeve assembly 130.

[0091] In various and non-limiting examples, the set of paddles 150 may be formed separably from the sleeve assembly 130. Thus, a set of sleeve recesses 160 may be machined or cast into the inner sleeve 134, the outer sleeve 132, or a combination thereof to receive one or more of the set of paddles 150. The set of paddles 150 may be held in place by frictional contact, engagement, adhesion, riveting, fastening, or a combination thereof with the set of sleeve recesses 160.

[0092] When the set of paddles 150 is formed separably from the sleeve assembly 130, in some examples, the set of paddles 150 may be provided to the set of sleeve recesses 160 after the composite spar 120 (e.g., as an uncured or partially cured material) is received in the sleeve assembly 130.

[0093] A set of spars recesses 162 may be machined into the composite spars 120 (e.g., as a cured or partially cured material) to receive the set of paddles 150. It is contemplated that the set of paddles 150 may be received by the composite spars 120 after it has been received in the sleeve assembly 130. Additionally or alternatively, the set of paddles 150 may be received by the sleeve assembly 130 or the composite spars 120 before a portion of the composite spars 120 is positioned in the sleeve assembly 130. The set of paddles 150 may be coupled to the composite spars 120 or the sleeve assembly 130 by bonding, adhesive, riveting, fastening, or a combination thereof. The set of paddles 150 may be spaced around a sleeve centerline 142. The set of paddles 150 may extend radially outward relative to the sleeve centerline 142.

[0094] The set of paddles 150 can extend from the paddle base 152 to the paddle tip 154 ​​in the spanwise direction (Sd). As shown, as a non-limiting example, the paddle base 152 can be aligned with the bottom portion 138 of the outer sleeve 132. The paddle length 156 can be measured in the spanwise direction (Sd) from the paddle base 152 to the paddle tip 154 ​​of each of the set of paddles 150. The paddle length 156 can range from 5% to 100% of the outer sleeve length 140. For example, the paddle length 156 can range from 10% to 50% of the outer sleeve length 140, including the endpoints. The benefits of this range include, but are not limited to, increasing the length from the airfoil body 110 ( Figure 3 Torque transmission is made via the composite spar 120 to the inner sleeve 134, the outer sleeve 132, or a combination thereof. Although shown as having a uniform paddle length 156, it is conceivable that the paddles in the set of paddles 150 may extend with different paddle lengths 156.

[0095] Each of the paddles 150 in the set can extend radially outward from the inner paddle end 172 to the outer paddle end 174 relative to the sleeve centerline 142. When the set of paddles 150 is formed together with or mounted to the sleeve assembly 130, the inner paddle end 172 can be the point of the paddle located at or closest to the radially outer surface 136 of the inner sleeve 134. Furthermore, when the set of paddles 150 is formed together with or mounted to the sleeve assembly 130, the outer paddle end 174 can be the point of the paddle located at or closest to the radially inner surface 133 of the outer sleeve 132. The paddle extension distance 176 can be measured perpendicularly to the sleeve centerline 142 from the inner paddle end 172 to the outer paddle end 174. Although the set of paddles 150 is shown to have a uniform paddle extension distance 176, the paddle extension distance of the paddles in the set of paddles 150 can vary between any two locations along the paddle length 156. As a non-limiting example, dashed line 178 shows the outer paddle end with a varying paddle extension distance 176.

[0096] When measured perpendicular to the sleeve centerline 142, the paddle extension distance 176 can be less than or substantially equal to the sparsity thickness 144. In the non-limiting example shown, the paddle extension distance 176 is less than the sparsity thickness 144. As used herein, "substantially equal to" means that one dimension differs from another by no more than 5%. That is, when the paddle extension distance 176 differs from the sparsity thickness 144 by no more than 5% or less, the paddle extension distance 176 is substantially equal to the sparsity thickness 144.

[0097] It is worth noting that, Figure 4 The number of paddles in the group of paddles 150 shown is selected only for illustrative purposes, and any number of paddles is possible, including having only one paddle. It is conceivable that the number of paddles can be adjusted according to the airfoil assembly 100 ( Figure 3 The number of paddles varies depending on the load conditions. In some examples, such as airfoil assemblies used under relatively small loads, a single paddle can be used to improve torque transmission and increase the ease of manufacturing and assembling the sleeve assembly 130. In various, non-limiting examples, such as airfoil assemblies used under relatively large loads, two or more paddles can be used to improve torque transmission and increase the surface area for transmitting torque loads. Further envisioning, depending on the number of spars, the load required to be transmitted, or any combination thereof, the number of paddles could be three or more.

[0098] The composite spar 120 may include a flared base 163. The flared base 163 may be a portion of the composite spar 120 that extends from the sleeve centerline 142 and is larger than the rest of the composite spar 120.

[0099] The flared base 163 may include a curved portion 164 adjacent to the parallel portion 166. The curved portion 164 may be part of the radially outer surface of the composite spar 120, forming a concave shape (as shown by example) or a convex shape relative to the sleeve centerline 142. Although shown with both a curved portion 164 and a parallel portion 166, it is contemplated that the flared base 163 may be either the curved portion 164 or the parallel portion 166. Furthermore, any number of curved or linear portions of the flared base 163 are contemplated. The curved portion 164 of the flared base 163 may further improve the engagement between the composite spar 120 and the sleeve assembly 130.

[0100] Figure 5 It shows along Figure 3 The figure shows a cross-sectional view of the composite spar 120 and sleeve assembly 130 along line VV. The composite spar 120 may include one or more spar preforms or lay-up pieces. A preform may include one or more layers of composite material molded to form a portion or piece of the composite spar 120. As shown, as a non-limiting example, the composite spar 120 may be a multi-piece composite spar and includes at least a first spar portion 192 and a second spar portion 194 as shown. The first spar portion 192 and the second spar portion 194 may include the same material, the same number of layers, the same reinforcing material, or any combination thereof. However, in different and non-limiting examples, it is contemplated that the first spar portion 192 and the second spar portion 194 may include different materials, different numbers of composite layers, different reinforcing materials, or any combination thereof.

[0101] The first wing spar section 192 and the second wing spar section 194 can be in the wingspan direction (Sd) ( Figure 4 Extending upwards, and defining a set of abutment portions 196a, 196b or dividing lines in the composite spar 120. The first spar portion 192 and the second spar portion 194 can be connected via this set of abutment portions 196a, 196b by any suitable method (such as, but not limited to, bonding, fastening, or a combination thereof). The first spar portion 192 and the second spar portion 194 can be arcuate about the sleeve centerline 142. That is, the first spar portion 192 and the second spar portion 194 can be arcuate about the inner sleeve 134 to surround or partially surround the inner sleeve 134.

[0102] At least one of the paddles 150 in the set can be located between the first spar portion 192 and the second spar portion 194. In other words, at least one paddle can be located at the abutment of the set of abutment portions 196a, 196b. As shown in the figure, as an example, the set of paddles 150 can include a first paddle 150a and a second paddle 150b. The first paddle 150a and the second paddle 150b can extend radially outward from the inner sleeve 134, wherein the second paddle 150b is circumferentially spaced from the first paddle 150a. The first paddle 150a and the second paddle 150b can be located at the abutment portions 196a, 196b between the first spar portion 192 and the second spar portion 194.

[0103] The paddle extension distance 176 of the first paddle 150a and the second paddle 150b is shown to be less than the spar thickness 144, which is measured from the radial inner surface 133 of the outer sleeve 132 and the radial outer surface 136 of the inner sleeve 134 after the composite spar 120 is received in the sleeve assembly 130.

[0104] Figure 6 It is used to form Figure 3-5 Method 200 for airfoil assembly 100 of a turbine engine (e.g., turbine engine 10).

[0105] At step 202, the sleeve assembly 130 may be formed of one or more metallic materials. The sleeve assembly 130 includes an outer sleeve 132 and an inner sleeve 134.

[0106] Alternatively, the sleeve assembly 130 may be machined or cast to include the set of sleeve recesses 160. That is, the set of sleeve recesses 160 may be machined, cast, or printed into the inner sleeve 134, the outer sleeve 132, or a combination thereof.

[0107] The set of paddles 150 may be formed of one or more metallic materials. One or more paddles in the set of paddles 150 may be separably formed from the sleeve assembly 130. The set of paddles 150 may be provided to the set of sleeve recesses 160 before or after the composite spar 120 is received in the sleeve assembly 130. The paddles in the set of paddles 150 may be held in place by frictional contact with the sleeve recesses in the set of sleeve recesses 160, and in some examples may include bonding, adhesive, riveting, fastening, or combinations thereof.

[0108] Alternatively, one or more of the paddles in the group can be integrally formed with the sleeve assembly 130. That is, the group of paddles 150 can be integrally formed with the inner sleeve 134, the outer sleeve 132, or a combination thereof.

[0109] At step 204, the composite spar 120 can be formed by laying down a composite material to produce one or more spar preforms. The composite spar 120 can be a multi-piece composite spar and includes at least two or more spar preforms. Therefore, the composite spar 120 can include at least a first spar portion 192 and a second spar portion 194. The first spar portion 192 and the second spar portion 194 can be joined or otherwise assembled to form the composite spar 120. The first spar portion 192 and the second spar portion 194 can be joined via the set of abutment portions 196a, 196b.

[0110] The composite spar 120 can be partially or fully cured. The spar recess 162 can be machined into the partially or fully cured composite spar 120.

[0111] Alternatively, at least a portion of the set of spar recesses 162 may be formed in the composite spar 120 prior to curing. That is, during the installation of the composite spar 120, a template, mold, or user may include recesses in the spar, which will result in the set of spar recesses 162 receiving the set of paddles 150.

[0112] Optionally, the composite spar 120 includes a spar core 170 formed of composite material or foam.

[0113] At step 206, the sleeve assembly 130 may receive the composite spar 120 such that the set of paddles 150 is received by the set of spar recesses 162. It is conceivable that the composite spar 120 is positioned relative to one or more portions of the sleeve assembly 130 before the set of paddles 150 is received in the set of spar recesses 162.

[0114] Optionally, the set of abutments 196a, 196b can be radially aligned with one or more recesses in the set of sleeve recesses 160 or one or more paddles in the set of paddles 150. Therefore, one or more paddles in the set of paddles 150 can be located between the first spar portion 192 and the second spar portion 194 (e.g., at one or both abutments 196a, 196b). The sleeve assembly 130, the composite spar 120, the set of paddles 150, or combinations thereof can be joined by welding, bonding, adhesive, riveting, fasteners, or combinations thereof.

[0115] In different and non-limiting examples, when a force is applied to the airfoil body 110 ( Figure 3 When the airfoil body 110 and the correspondingly connected composite spar 120 rotate, the friction between the composite spar 120 and the sleeve assembly 130 can at least partially prevent the airfoil body 110 ( Figure 3 ) and rotation in the composite spar 120.

[0116] Figure 7 It shows the relationship with Figure 4 The sleeve assembly 130 and the composite spar 120 are similar to the sleeve assembly 230 and the composite spar 220. Therefore, similar parts will be identified by similar numbers increased by one hundred (100), and it should be understood that unless otherwise stated, the sleeve assembly 130 and the composite spar 120 ( Figure 4 The description can be applied to sleeve assembly 230 and composite spar 220.

[0117] The sleeve assembly 230 includes an outer sleeve 232 and an inner sleeve 234. The outer sleeve 232 has a radially outer surface 231 and a radially inner surface 233. A sleeve centerline 242 may be centrally defined within the outer sleeve 232. The inner sleeve 234 has a radially inner surface 235 and a radially outer surface 236. The inner sleeve 234 may be at least partially positioned within a portion of the hollow interior of the outer sleeve 232.

[0118] A set of sleeve recesses 260 may include recesses in an inner sleeve 234, an outer sleeve 232, or a combination thereof. A set of spar recesses 262 may correspond to the set of sleeve recesses 260.

[0119] A set of paddles 250 can be received by the set of sleeve recesses 260 and the set of spar recesses 262. The set of paddles 250 can extend from the paddle base 252 to the paddle tip 254 in the spanwise direction (Sd). The set of paddles 250 is shown as a first paddle 250a and a second paddle 250b. The set of paddles 250 can span the spar thickness 244. That is, one or more of the paddles 250 extend between the inner sleeve 234 and the outer sleeve 232 or connect the inner sleeve 234 to the outer sleeve 232. In this configuration, the paddle extension distance 276 is substantially equal to the spar thickness 244.

[0120] Figure 8 It shows along Figure 7 Cross-sectional view of the composite spar 220 and sleeve assembly 230 along lines VIII-VIII shown.

[0121] As an example, the composite spar 220 is shown as being defined by a first spar portion 292 and a second spar portion 294. The first spar portion 292 and the second spar portion 294 intersect at two locations to define a set of abutment portions 296a, 296b. A first paddle 250a and a second paddle 250b may be located between the first spar portion 292 and the second spar portion 294.

[0122] Each of the paddles in the group 250 extends radially outward from the inner paddle end 272, which is located on or closest to the radial outer surface 236 of the inner sleeve 234, relative to the sleeve centerline 142, to the outer paddle end 274, which is located on or closest to the radial inner surface 133 of the outer sleeve 132.

[0123] In some examples, as shown, when the paddles in the group of paddles are formed separately from the sleeve assembly 230, the paddles may include portions extending radially inward from the inner paddle end 272 to define the innermost paddle end 258, portions extending radially outward from the outer paddle end 274 to define the outermost paddle end 259, or both. The total paddle width 251 may be measured from the innermost paddle end 258 to the outermost paddle end 259. The total paddle width 251 may be greater than the sparsity thickness 244, the paddle extension distance 276, or both.

[0124] Alternatively, as a non-limiting example, the set of paddles 250 may be integrally formed with the inner sleeve 234 and received by a recess in the set of sleeve recesses 260 located in the outer sleeve 232. In this configuration, the innermost paddle end 258 is defined at the inner paddle end 272, and the total paddle width may be measured from the inner paddle end 272 to the outermost paddle end 259.

[0125] Optionally, the set of paddles 250 may include a third paddle 250c radially spaced from the first paddle 250a and the second paddle 250b. As an example, the third paddle 250c is shown attached to the inner sleeve 234. That is, a portion of the third paddle 250c may be received by the inner sleeve 234. Alternatively, the third paddle 250c may be integrally formed with the inner sleeve 234.

[0126] As an example, the third paddle 250c is located at the second spar portion 294. That is, a set of spar recesses 262 may include recesses at the set of abutments 296a, 296b to receive at least the first paddle 250a and the second paddle 250b, and may also include one or more recesses of the first spar portion 292, the second spar portion 294, or combinations thereof to receive any number of additional paddles in the set of paddles 150.

[0127] Figure 9 It shows the relationship with Figure 4 and Figure 7The sleeve assemblies 130, 230 and the composite spars 120, 220 are similar to the composite spar 320 and the sleeve assembly 330. Therefore, similar parts will be identified by similar numbers further increased by one hundred (100), and it should be understood that, unless otherwise stated, the description of the sleeve assemblies 130, 230 and the composite spars 120, 220 can be applied to the sleeve assembly 330 and the composite spar 320.

[0128] The sleeve assembly 330 includes an outer sleeve 332 and an inner sleeve 334. The outer sleeve 332 has a radially outer surface 331 and a radially inner surface 333. A sleeve centerline 342 may be centrally defined within the outer sleeve 332. The inner sleeve 334 has a radially inner surface 335 and a radially outer surface 336. The inner sleeve 334 may be at least partially positioned within a portion of the hollow interior of the outer sleeve 332.

[0129] A set of sleeve recesses 360 may include recesses in an inner sleeve 334, an outer sleeve 332, or a combination thereof. A set of spar recesses 362 may correspond to the set of sleeve recesses 360.

[0130] A set of paddles 350 can be received by a set of sleeve recesses 360 and a set of spar recesses 362. Each paddle in the set of paddles 350 can extend radially outward from the inner paddle end 372 relative to the sleeve centerline 342 to the outer paddle end 374. The set of paddles 350 is shown as a first paddle 350a, a second paddle 350b, and a third paddle 350c.

[0131] As an example, the composite spar 320 is shown as being defined by a first spar portion 392 and a second spar portion 394. The first spar portion 392 and the second spar portion 394 intersect at two locations to define a set of abutment portions 396a, 396b.

[0132] As an example, the first paddle 350a and the second paddle 350b are shown extending from the inner sleeve 334 to the outer sleeve 332. As an example, the first paddle 350a and the second paddle 350b are located at the intersection of the first spar portion 392 and the second spar portion 394. That is, the first paddle 350a and the second paddle 350b are located at the set of abutment portions 396a and 396b.

[0133] As an example, the third paddle 350c is shown attached to the outer sleeve 332. That is, a portion of the third paddle 350c may be received by the outer sleeve 332. Alternatively, the third paddle 350c may be integrally formed with the outer sleeve 332.

[0134] As an example, the third paddle 350c is located at the second spar portion 394. That is, a set of spar recesses 362 may include recesses at the set of abutments 396a, 396b, and one or more recesses at the first spar portion 392, the second spar portion 394, or any combination thereof.

[0135] Benefits associated with the composite spars described herein include improved engagement between the composite spars and the sleeve assembly. Additional benefits include improved torque transfer from the composite spars to the metal sleeves under load conditions due to the set of paddles extending between the inner and outer sleeves. This set of paddles can support adjacent sleeve assemblies and composite spars to improve or resist rotation about a common axis (e.g., the pitch axis (Pax)). In some examples, the airfoil body and the correspondingly coupled composite spars can rotate about the pitch axis (Pax) when the load is received by the airfoil body. This set of paddles can provide redundant load paths, where the load is not only received by the connection between the composite spars and the inner and outer sleeves. This additional load path essentially bears shear loads between the composite spars and the inner and outer metal sleeves and translates them into circumferential loads within the fibers of the composite wrapper or composite body.

[0136] Additional benefits may include improved bonding between the composite and metal materials, as the paddlewheel secures the composite spars to the metal sleeve. This improved bonding allows for the securing of the composite and metal materials without the need for adhesives or adhesive wear. The improved bonding also helps secure the composite and metal materials during ingestion events or other high-load events.

[0137] Another benefit is that composite spars are lighter than metal spars and still provide strength and durability within the airfoil assembly.

[0138] Further aspects of this disclosure are provided by the subject matter of the following clauses:

[0139] An airfoil assembly for an engine, the airfoil assembly comprising: an airfoil body including an outer wall defining an interior, the outer wall extending between a leading edge and a trailing edge in a chordal direction and between a root and a tip in a spanwise direction; a composite sparsity having an inner sparsity portion located inside the airfoil body and an outer sparsity portion located outside the airfoil body; a sleeve assembly including an outer sleeve and an inner sleeve surrounded by the outer sleeve, wherein at least a portion of the outer sparsity portion of the composite sparsity is received at a radially outer surface of the inner sleeve; and a set of paddles extending from the inner sleeve or the outer sleeve toward another of the inner sleeve or the outer sleeve.

[0140] Airfoil assembly according to any of the foregoing clauses, wherein the airfoil assembly is a variable pitch airfoil assembly.

[0141] According to any of the foregoing clauses, the airfoil assembly wherein the set of paddle-shaped elements is metallic.

[0142] According to any of the foregoing clauses, the airfoil assembly, wherein the composite spar includes at least a first spar portion and a second spar portion, wherein the first spar portion and the second spar portion extend in the span direction, and a set of abutments is defined between the first spar portion and the second spar portion.

[0143] According to any of the foregoing clauses, in the airfoil assembly, at least a portion of the outer spar portion is received at the radially inner surface of the outer sleeve.

[0144] According to any of the foregoing clauses, the airfoil assembly, wherein the sleeve assembly defines a sleeve centerline and a spar thickness measured perpendicular to the sleeve centerline from the radially outer surface of the inner sleeve to the radially inner surface of the outer sleeve.

[0145] According to any of the foregoing clauses, in the airfoil assembly, at least one of the paddles has a paddle extension distance measured from the inner paddle end located at the radially outer surface of the inner sleeve toward the outer sleeve to the outer paddle end, and wherein the paddle extension distance is less than the sparsity thickness.

[0146] According to any of the preceding clauses, in the airfoil assembly, at least one of the paddles has a paddle extension distance measured from the inner paddle end located at the radially outer surface of the inner sleeve toward the outer sleeve to the outer paddle end, and wherein the paddle extension distance is equal to the sparsity thickness.

[0147] According to any of the foregoing clauses, the airfoil assembly, wherein the composite spar includes at least a first spar portion and a second spar portion, wherein at least one of the group of paddles is located between the first spar portion and the second spar portion.

[0148] According to any of the foregoing clauses, in the airfoil assembly, at least one of the group of paddles extends radially outward from the inner sleeve and is received by a sleeve recess in the radially inner surface of the outer sleeve.

[0149] According to any of the foregoing clauses, the airfoil assembly, wherein the composite spar includes at least a first spar portion and a second spar portion, wherein at least one of the group of paddles is located between the first spar portion and the second spar portion.

[0150] According to any of the foregoing clauses, the airfoil assembly wherein the at least one paddle is a first paddle, and the set of paddles further includes a second paddle extending radially outward from the inner sleeve.

[0151] According to any of the foregoing clauses, the second paddle is circumferentially spaced from the first paddle and located between the first spar portion and the second spar portion.

[0152] According to any of the foregoing clauses, the airfoil assembly wherein the second paddle extends from an inner paddle end at the radially outer surface of the inner sleeve to an outer paddle end located between the radially outer surface of the inner sleeve and the radially inner surface of the outer sleeve.

[0153] According to any of the foregoing clauses, the airfoil assembly, wherein the composite spar includes at least a first spar portion and a second spar portion, wherein the set of paddles includes a first paddle located between the first spar portion and the second spar portion, a second paddle located between the first spar portion and the second spar portion, and the second paddle is circumferentially spaced from the first paddle.

[0154] According to any of the foregoing clauses, the third paddle of the group of paddles is circumferentially spaced from the first and second paddles, and the third paddle extends radially from the outer sleeve through one of the first spar portion or the second spar portion.

[0155] According to any of the foregoing clauses, in the airfoil assembly, a third paddle of the group of paddles is circumferentially spaced from the first paddle and the second paddle, and the third paddle extends from the inner sleeve through at least a portion of the first spar portion or at least a portion of the second spar portion.

[0156] According to any of the foregoing clauses, the airfoil assembly wherein the second paddle extends from an inner paddle end at the radially outer surface of the inner sleeve to an outer paddle end at a recess in the radially inner surface of the outer sleeve.

[0157] According to any of the foregoing clauses, in the airfoil assembly, a third paddle of the set of paddles is circumferentially spaced from the first and second paddles, the third paddle extends radially outward to the radially inner surface of the outer sleeve, and the third paddle passes through a portion of the first spar or the second spar.

[0158] According to any of the foregoing clauses, the airfoil assembly, wherein the set of paddles comprises only one paddle.

[0159] According to any of the foregoing clauses, the inner sleeve has an inner sleeve length measured in the span direction, the outer sleeve has an outer sleeve length measured in the span direction, and the length of the inner sleeve is 30-60% of the length of the outer sleeve.

[0160] According to any of the foregoing clauses, each of the group of paddles has a paddle length measured in the wingspan direction, and the paddle length is 5% to 100% of the outer sleeve length.

[0161] According to any of the foregoing clauses, the airfoil assembly, wherein the length of the paddle is 10% to 50% of the length of the outer sleeve, including the end points.

[0162] Airfoil assembly according to any of the foregoing clauses, wherein the airfoil assembly is mounted in a fixed arrangement.

[0163] According to any of the foregoing clauses, the airfoil assembly is coupled to the fan pitch actuation system.

[0164] According to any of the foregoing clauses, the airfoil assembly further includes a spar core comprising a composite material coupled to an axial end of the inner sleeve.

[0165] According to any of the foregoing clauses, the airfoil assembly further includes a transition portion connecting the spar core and the axial end of the inner sleeve.

[0166] According to any of the foregoing clauses, in the airfoil assembly, at least one of the group of paddles is integrally formed with the sleeve assembly.

[0167] According to any of the foregoing clauses, in the airfoil assembly, at least one of the group of paddles is detachably formed from the sleeve assembly.

[0168] According to any of the foregoing clauses, in the airfoil assembly, at least one of the group of paddles is detachably formed from the sleeve assembly.

[0169] According to any of the foregoing clauses, the airfoil assembly, wherein the composite spar includes a flared base.

[0170] According to any of the foregoing clauses, in the airfoil assembly, at least one of the group of paddles extends radially outward from the outer sleeve into one or both of the first spar portion and the second spar portion.

[0171] According to any of the foregoing clauses, the paddle length is measured from the paddle base to the paddle tip in the wingspan direction, and the paddle extension distance of at least one of the paddles varies along the paddle length.

[0172] A turbine engine includes: a fan section, a compressor section, a combustion section, and a turbine section arranged in a series flow configuration and defining an engine centerline; and an airfoil assembly rotatable about the engine centerline, the airfoil assembly including: an airfoil body including an outer wall defining an interior, the outer wall extending between a leading edge and a trailing edge in a chordal direction and between a root and a tip in a spanwise direction; a composite spars having an inner spars portion located inside the airfoil body and an outer spars portion located outside the airfoil body, the composite spars including at least a first spars portion and a second spars portion; a sleeve assembly including an outer sleeve and an inner sleeve surrounded by the outer sleeve, wherein at least a portion of the outer spars portion of the composite spars is received at a radially outer surface of the inner sleeve; and a set of paddles extending from the inner sleeve or the outer sleeve toward another of the inner sleeve or the outer sleeve.

[0173] According to any of the preceding clauses, the turbine engine comprises at least a first spar portion and a second spar portion, wherein at least one of the set of paddles is located between the first spar portion and the second spar portion.

[0174] The turbine engine according to any of the foregoing clauses, wherein the airfoil assembly is disposed within the fan section.

[0175] The turbine engine according to any of the foregoing clauses, wherein the airfoil assembly is a variable pitch airfoil assembly.

[0176] The turbine engine according to any of the foregoing clauses, wherein the set of propellers is metallic.

[0177] According to any of the preceding clauses, the turbine engine, wherein the composite spar includes at least a first spar portion and a second spar portion, wherein the first spar portion and the second spar portion extend in the span direction, and a set of abutments is defined between the first spar portion and the second spar portion.

[0178] According to any of the foregoing clauses, in a turbine engine, at least a portion of the outer spar portion is received at the radially inner surface of the outer sleeve.

[0179] According to any of the preceding clauses, the turbine engine wherein the sleeve assembly defines a sleeve centerline and a sparsity thickness measured perpendicular to the sleeve centerline from the radially outer surface of the inner sleeve to the radially inner surface of the outer sleeve.

[0180] According to any of the preceding clauses, in a turbine engine, at least one of the propellers has a propeller extension distance measured from an inner propeller end located at the radially outer surface of the inner sleeve toward the outer sleeve to an outer propeller end, and wherein the propeller extension distance is less than the sparsity thickness.

[0181] According to any of the preceding clauses, in a turbine engine, at least one of the propellers has a propeller extension distance measured from an inner propeller end located at the radially outer surface of the inner sleeve toward the outer sleeve to an outer propeller end, and wherein the propeller extension distance is equal to the sparsity thickness.

[0182] According to any of the preceding clauses, in a turbine engine, at least one of the set of paddles extends radially outward from the inner sleeve and is received by a sleeve recess in the radially inner surface of the outer sleeve.

[0183] According to any of the preceding clauses, the turbine engine comprises at least a first spar portion and a second spar portion, wherein at least one of the set of paddles is located between the first spar portion and the second spar portion.

[0184] The turbine engine according to any of the foregoing clauses, wherein the at least one paddle is a first paddle, and the set of paddles further includes a second paddle extending radially outward from the inner sleeve.

[0185] According to any of the foregoing clauses, the turbine engine wherein the second propeller is circumferentially spaced from the first propeller and is located between the first spar portion and the second spar portion.

[0186] According to any of the preceding clauses of the turbine engine, wherein the second paddle extends from an inner paddle end at the radially outer surface of the inner sleeve to an outer paddle end located between the radially outer surface of the inner sleeve and the radially inner surface of the outer sleeve.

[0187] According to any of the preceding clauses, the turbine engine, wherein the composite spar includes at least a first spar portion and a second spar portion, wherein the set of paddles includes a first paddle located between the first spar portion and the second spar portion, a second paddle located between the first spar portion and the second spar portion, and the second paddle is circumferentially spaced from the first paddle.

[0188] According to any of the foregoing clauses, in a turbine engine, a third propeller of the set of propellers is circumferentially spaced from the first and second propellers, and the third propeller extends radially from the outer sleeve through one of the first spar portion or the second spar portion.

[0189] According to any of the preceding clauses, in a turbine engine, a third propeller of the set of propellers is circumferentially spaced from the first and second propellers, and the third propeller extends from the inner sleeve through at least a portion of the first spar portion or at least a portion of the second spar portion.

[0190] According to any of the preceding clauses, in a turbine engine, the second paddle extends from an inner paddle end at the radially outer surface of the inner sleeve to an outer paddle end at a recess in the radially inner surface of the outer sleeve.

[0191] According to any of the preceding clauses, in a turbine engine, the second paddle extends from an inner paddle end at the radially outer surface of the inner sleeve to an outer paddle end at a recess in the radially inner surface of the outer sleeve.

[0192] According to any of the preceding clauses, in a turbine engine, a third propeller of the set of propellers is circumferentially spaced from the first and second propellers, the third propeller extends radially outward to the radially inner surface of the outer sleeve, and the third propeller passes through a portion of the first spar or the second spar.

[0193] The turbine engine according to any of the foregoing clauses, wherein the set of paddles comprises only one paddle.

[0194] According to any of the preceding clauses, the inner sleeve has an inner sleeve length measured in the span direction, the outer sleeve has an outer sleeve length measured in the span direction, and the length of the inner sleeve is 30-60% of the length of the outer sleeve.

[0195] According to any of the preceding clauses, each of the set of propellers has a propeller length measured in the wingspan direction, and the propeller length is 5% to 100% of the outer sleeve length.

[0196] The turbine engine according to any of the foregoing clauses, wherein the length of the paddle is 10% to 50% of the length of the outer casing, including the end points.

[0197] The turbine engine according to any of the foregoing clauses, wherein the airfoil assembly is mounted in a fixed arrangement.

[0198] The turbine engine according to any of the foregoing clauses, wherein the sleeve assembly is coupled to the fan pitch actuation system.

[0199] The turbine engine according to any of the foregoing clauses, wherein the sleeve assembly further includes a sparsity core comprising a composite material coupled to an axial end of the inner sleeve.

[0200] According to any of the foregoing clauses, the turbine engine wherein the sleeve assembly further includes a transition portion connecting the axial end of the spar core and the inner sleeve.

[0201] The turbine engine according to any of the foregoing clauses, wherein at least one of the group of paddles is integrally formed with the sleeve assembly.

[0202] The turbine engine according to any of the foregoing clauses, wherein at least one of the group of paddles is detachably formed from the sleeve assembly.

[0203] The turbine engine according to any of the foregoing clauses, wherein at least one of the group of paddles is detachably formed from the sleeve assembly.

[0204] The turbine engine according to any of the foregoing clauses, wherein the composite spar includes a flared base.

[0205] According to any of the preceding clauses, in a turbine engine, at least one of the set of paddles extends radially outward from the outer casing into one or both of the first spar portion and the second spar portion.

[0206] According to any of the preceding clauses, the propeller length is measured from the base of the propeller to the tip of the propeller in the wingspan direction, and the propeller extension distance of at least one of the group of propellers varies along the propeller length.

Claims

1. An airfoil assembly for an engine, characterized in that, The airfoil assembly includes: An airfoil body, the airfoil body including an outer wall defining an interior, the outer wall extending between a leading edge and a trailing edge in a chordal direction and between a root and a tip in a spanwise direction; A composite wing sparb having an inner wing sparb portion located inside the airfoil body and an outer wing sparb portion located outside the airfoil body; A sleeve assembly, the sleeve assembly including an outer sleeve and an inner sleeve surrounded by the outer sleeve, wherein at least a portion of the outer spar portion of the composite spar is received at the radially outer surface of the inner sleeve; and A set of paddle-shaped objects extending from the inner sleeve or the outer sleeve toward another of the inner sleeve or the outer sleeve.

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

3. The airfoil assembly according to claim 1, characterized in that, in, The set of paddle-shaped objects is metallic.

4. The airfoil assembly according to claim 1, characterized in that, in, The composite spar includes at least a first spar portion and a second spar portion, wherein the first spar portion and the second spar portion extend in the span direction, and a set of abutments is defined between the first spar portion and the second spar portion.

5. The airfoil assembly according to claim 1, characterized in that, in, At least a portion of the outer wing spar is received at the radial inner surface of the outer sleeve.

6. The airfoil assembly according to claim 5, characterized in that, in, The sleeve assembly defines a sleeve centerline, and the spar thickness is measured perpendicular to the sleeve centerline from the radially outer surface of the inner sleeve to the radially inner surface of the outer sleeve.

7. The airfoil assembly according to claim 6, characterized in that, in, At least one of the paddles in the group has a paddle extension distance measured from the inner paddle end located at the radial outer surface of the inner sleeve toward the outer sleeve to the outer paddle end, and wherein the paddle extension distance is less than the spar thickness.

8. The airfoil assembly according to claim 6, characterized in that, in, At least one of the paddles in the group has a paddle extension distance measured from the inner paddle end located on the radially outer surface of the inner sleeve toward the outer sleeve to the outer paddle end, and wherein the paddle extension distance is equal to the spar thickness.

9. The airfoil assembly according to claim 1, characterized in that, in, The composite spar includes at least a first spar portion and a second spar portion, wherein at least one of the paddle-shaped elements is located between the first spar portion and the second spar portion.

10. The airfoil assembly according to claim 1, characterized in that, in, At least one of the paddles in the set extends radially outward from the inner sleeve and is received by a sleeve recess in the radially inner surface of the outer sleeve.

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