Carbon Fiber Engine Intake Guard with Tri-Axial Weave
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Solution Overview
Problem
Current aircraft engine protection devices are ineffective in preventing foreign bodies from entering the engine intake without increasing the aircraft's profile or using hazardous materials, and they can cause additional damage if damaged.
Innovation Solution
A carbon fiber woven engine intake guard with three interconnected modules that fit within the engine nacelle, providing progressive protection levels without altering the aircraft's profile and using a novel tri-layer weaving method to create a lightweight, aerodynamic screen that captures foreign objects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a protective screen is mounted at the front of the engine intake to prevent foreign bodies, then foreign body protection is improved, but the aircraft profile is extended and weight increases
Solution Approach 1:
The protective screen is nested within the existing engine nacelle structure, fitting inside the cone-shaped nacelle rather than extending outward. This allows the protection device to be contained within the existing aircraft profile, avoiding extension of the aircraft length while still providing effective foreign body protection at the engine intake.
Solution Approach 2:
The protective screen is constructed as a thin, flexible mesh structure that can be formed into a cone shape fitting within the nacelle. This thin-film approach provides protection while minimizing added weight and maintaining the original aircraft profile, unlike rigid metal constructions that would extend the profile.
2Strength
If a metal rod and bar mesh guard is used to prevent foreign bodies, then protection strength is improved, but the device becomes hazardous if damaged and weight increases
Solution Approach 1:
The protective screen uses a composite construction combining a flexible mesh outer layer with an inner reinforcement structure. This composite design provides the necessary strength to prevent foreign body penetration while using non-metallic or low-hazard materials that do not generate dangerous shrapnel if damaged, eliminating the hazard associated with traditional metal mesh guards.
Solution Approach 2:
The guard material is changed from traditional metal to a non-metallic or composite material that maintains structural integrity for protection but eliminates the shrapnel hazard. The material parameters are selected to provide sufficient strength for foreign body protection while ensuring that failure does not create harmful debris.
3Reliability
If a dense mesh guard is used to prevent foreign bodies, then protection effectiveness is improved, but air intake is restricted and engine thrust is reduced
Solution Approach 1:
The protective screen employs a mesh structure with optimized opening sizes and distributions that provide effective foreign body protection while maintaining adequate air intake areas. The mesh design allows air to pass through freely while blocking foreign objects, balancing protection effectiveness with engine thrust requirements.
Solution Approach 2:
The protective screen uses a porous mesh structure that allows air to pass through while blocking foreign bodies. The porous design maintains open pathways for air intake, ensuring that engine thrust is not significantly reduced while still providing effective protection against foreign object intrusion.
Data Source
AI summary
A jet engine intake guard includes an engine sleeve located within the nacelle of the engine; a primary deflection screen located at a front portion of the sleeve and having a first circular frame formed of a tubular fabric member and a plurality of fiber yarn strings disposed across the diameter of the primary frame and attached to one another in a tri-axel weave pattern. The guard also includes a secondary deflection screen located behind the primary deflection screen in the direction of air flow through the engine and having a second circular frame formed of a tubular fabric member and a plurality of fiber yarn strings disposed across the secondary frame and attached to one another in a tri-axel weave pattern. The guard further includes a capture basket located between the primary and secondary deflection screens. The capture basket has a first wall located toward the primary deflection screen, a center portion and a second wall located toward the secondary deflection screen. In a preferred embodiment the entire guard is made of woven carbon fiber.