Composite Airfoil Spar-Root Assembly for High-Temperature Turbines

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Solution Overview

Problem

Existing turbine engine airfoils, particularly those made of composite materials, face challenges in achieving a high strength-to-weight ratio while maintaining performance in high-temperature environments, especially in the turbine sections of gas turbine engines.

Innovation Solution

The use of a composite airfoil assembly comprising a triaxially braided carbon fiber spar assembly integrated with a root assembly, formed using resin transfer molding and incorporating preforms and a fiber skin layer, which enhances structural integrity and reduces weight.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If composite materials are used in turbine engine airfoils, then weight is reduced and strength-to-weight ratio is improved, but maintaining performance in high-temperature environments becomes challenging

Engineering Contradiction:

Improveairfoil weightVSAvoidhigh-temperature environment performance

Core Design Contradiction:

Weight of moving objectVSTemperature

Solution Approach 1:

The patent applies composite materials consisting of a matrix material and a reinforcement material (such as continuous fibers, discontinuous fibers, or whiskers) to create airfoils that maintain both low weight and high-temperature performance. The composite structure allows the material to withstand turbine section temperatures while preserving the weight advantages of composite construction.

Inventive Principle:

Principle #40Composite materials

2Strength

If composite materials are used in turbine engine airfoils, then strength-to-weight ratio is improved, but structural integrity in high-temperature sections is compromised

Engineering Contradiction:

Improvestrength-to-weight ratioVSAvoidstructural integrity in high-temperature sections

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent employs composite materials with a matrix material combined with reinforcement materials (continuous fibers, discontinuous fibers, or whiskers) to achieve both high strength-to-weight ratio and structural integrity in high-temperature turbine sections. The reinforcement materials provide the necessary structural stability under thermal stress.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent modifies the material parameters by selecting matrix materials and reinforcement materials with specific properties that maintain structural integrity at high temperatures. This includes choosing materials with appropriate melting points, thermal stability, and mechanical properties that remain effective in the turbine temperature range.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentEP4717594A1Composite airfoil assembly

Publication Date: 2026.04.01 GE AVIATION SYST LTD

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AI summary

A composite airfoil assembly (100) and method of forming includes a spar assembly (120) with a spar core (126) and a spar fiber layer (128) at least partially surrounding the spar core (126), as well as a root assembly (130) with a sleeve assembly (127) carrying a set of spaced wedges (135) defining at least one slot (136) configured to receive a first end (121) of the spar assembly (120).