Composite Airfoil Core-and-Wrap Structure for Turbine Engines
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Solution Overview
Problem
Existing turbine engine components, particularly in high-temperature regions, face challenges in achieving a balance between strength, weight, and complex shape requirements, as traditional materials do not adequately address these factors.
Innovation Solution
The use of a composite airfoil with a plies core and composite wrap, which includes a set of composite plies and a spar core, provides enhanced strength and structural integrity while maintaining a lightweight design, suitable for complex shapes and high-temperature environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional materials are used in high-temperature regions of turbine engines, then manufacturing and structural simplicity are maintained, but strength and weight requirements cannot be adequately balanced
Solution Approach 1:
The patent applies composite materials consisting of a fiber-reinforced matrix to manufacture turbine engine components. The composite structure combines discrete fibers embedded in a matrix material, providing enhanced strength-to-weight ratio while enabling complex geometric shapes through molding processes. This resolves the contradiction by simultaneously achieving high strength requirements and complex shape capabilities that traditional monolithic materials cannot provide.
2Weight of moving object
If composite materials are used to reduce weight, then weight savings are achieved, but structural integrity and strength in high-temperature regions may be compromised
Solution Approach 1:
The patent implements local quality by varying the fiber orientation, density, and material composition in different regions of the composite component. High-strength fiber configurations are concentrated in areas subject to high thermal and mechanical loads, while other regions use optimized compositions for weight reduction. This localized optimization maintains structural integrity in critical zones while achieving overall weight savings.
Solution Approach 2:
The patent utilizes parameter changes by adjusting the fiber-to-matrix ratio, fiber orientation angles, and material composition based on local thermal and mechanical conditions. In high-temperature regions, the composite structure incorporates parameters optimized for thermal stability and strength, while other regions use parameters optimized for weight reduction, thereby maintaining reliability across the entire component.
3Weight of moving object
If composite materials with high strength to weight ratio are used, then weight savings and strength are improved, but manufacturing complexity and process difficulty increase
Solution Approach 1:
The patent applies preliminary action by pre-positioning fibers in desired orientations and pre-impregnating them with matrix material before final component formation. This preliminary preparation of the composite structure simplifies the subsequent manufacturing process by eliminating complex step-by-step assembly operations, thereby reducing manufacturing complexity while maintaining the weight and strength benefits of composite materials.
Data Source
AI summary
A composite airfoil for a turbine engine, the composite airfoil having at least one airfoil body element. The at least one airfoil body element includes a core and a composite wrap, where the composite wrap overlies at least a portion of the core. The core includes a set of composite plies.