Ceramic Tile Fan Blade Containment with Elastomeric Adhesive
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Solution Overview
Problem
Existing fan blade containment systems using ceramic tiles face challenges with thermal expansion mismatch and long bond times due to the use of RTV sealants, leading to inconsistent bondlines and gaps, which can compromise the retention of fan blade fragments during engine operation.
Innovation Solution
A fan blade containment system utilizing annular ceramic tiles with elastomeric adhesive layers, including double-sided adhesive foam tape, and scarfed edges to ensure a consistent and gap-free bond, while managing thermal expansion mismatch and allowing for rapid curing compatible with high-temperature cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If RTV sealant is used to attach ceramic tiles to the containment structure, then thermal expansion mismatch is abated, but bondline consistency deteriorates and gaps form between tiles
Solution Approach 1:
A compliant adhesive layer is introduced as an intermediary between the ceramic tiles and the containment structure. This adhesive layer specifically addresses the thermal expansion mismatch between dissimilar materials while providing consistent bonding without gaps, resolving both the thermal compatibility and manufacturing precision issues simultaneously.
Solution Approach 2:
The invention changes the physical and chemical parameters of the adhesive material to achieve optimal performance. By selecting an adhesive with specific properties (compliance, thermal stability, bonding strength), the system achieves both thermal expansion compatibility and consistent bondline formation, eliminating the trade-off between these parameters.
2Adaptability or versatility
If RTV sealant is used to attach ceramic tiles, then thermal expansion mismatch is managed, but cure time increases significantly
Solution Approach 1:
The invention changes the chemical composition and curing characteristics of the adhesive material. By selecting an adhesive with faster cure kinetics while maintaining thermal compliance, the system achieves both thermal expansion management and reduced cure time, eliminating the trade-off between these parameters.
3Adaptability or versatility
If RTV sealant is used for ceramic tile attachment, then thermal expansion is accommodated, but compatibility with high temperature cure cycles deteriorates
Solution Approach 1:
The invention changes the thermal and chemical stability parameters of the adhesive material. By selecting an adhesive that can withstand high temperature cure cycles while maintaining its compliant properties, the system achieves both thermal expansion compatibility and reliability under subsequent processing conditions, resolving the trade-off between these parameters.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a reliable and lightweight containment system with consistent bondlines, reduced cycle times, and compatibility with high-temperature processes, effectively retaining fan blade fragments without increasing engine weight.
Implementation Method 1
thermal expansion mismatch and high modulus will cause disbonds between the ceramic and containment structure. A rubber or elastomeric layer (typically RTV or sealant materials such as polysulfide) between the ceramic and structure can abate a Coefficient of Thermal Expansion (CTE) mismatch between the ceramic tiles and structure supporting the ceramic tiles.
Implementation Method 2
A rubber or elastomeric layer (typically RTV or sealant materials such as polysulfide) between the ceramic and structure can abate a Coefficient of Thermal Expansion (CTE) mismatch
Data Source
AI summary
Fan blade containment system includes circular tile layer of annular ceramic tiles attached to and extending radially inwardly from a shell, radially inner and outer annular surfaces of ceramic tiles bonded to a radially inner composite layer and the shell respectively with elastomeric inner and outer adhesive layers respectively. Elastomeric adhesive layers between circumferentially adjacent overlapped or scarfed edges along circumferential edges of the ceramic tiles overlap and mate along oppositely facing surfaces of adjacent ones of the ceramic tiles. Inner and outer adhesive layers and elastomeric adhesive layer may be a double-sided adhesive foam tape. Scarfed edges may be bevels or rabbets. Shell may be made of a metal or composite material. Fan blade containment system may be bonded to and extend inwardly from fan case circumscribing fan blades of a fan. Inner composite layer and composite outer shell may be co-cured with ceramic tiles therebetween.