Composite Turbine Airfoil Wrap Structure for High-Temperature Strength
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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, with composite materials not fully addressing these needs.
Innovation Solution
A composite airfoil design incorporating a plies core and composite wrap, which provides enhanced strength and structural integrity through a wrap-around feature, along with a spar core for additional support, utilizing polymer matrix composite plies and ceramic matrix composites for higher temperature applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If composite materials are used in turbine engine components, then weight is reduced and strength to weight ratio is improved, but strength and structural integrity in high-temperature regions are insufficient
Solution Approach 1:
The patent applies composite materials consisting of a foam core with integrated composite wraps and skin panels. The foam core provides structural support while the composite wraps (including spiral wraps, helical wraps, and longitudinal wraps) and skin panels provide strength and structural integrity. This composite structure achieves both weight reduction and enhanced strength, particularly in high-temperature regions where traditional composites have been insufficient.
2Shape
If composite materials are used to achieve complex shapes, then moldability is improved, but strength and durability under impact events are insufficient
Solution Approach 1:
The patent employs a multi-layer composite structure where foam core material is wrapped with multiple layers of composite material in different orientations (spiral, helical, longitudinal wraps). This composite construction provides both the complex aerodynamic shapes required for airfoils and the enhanced strength to withstand impact events, combining the moldability advantage of composites with improved structural durability.
3Ease of manufacture
If traditional composite structures are used, then manufacturing is simplified, but strength through thickness is insufficient
Solution Approach 1:
The patent introduces a three-dimensional wrap-around structure where composite material wraps spirally, helically, and longitudinally around the foam core. This dimensional approach to reinforcement provides strength through the thickness of the component while maintaining ease of manufacture through a systematic wrapping process. The wrap-around configuration creates interlocking layers that enhance through-thickness strength without complicating the manufacturing process.
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.