Composite Turbomachinery Base Plate for Low-Profile Vibration Damping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current base plate structures for gas turbine engines are labor-intensive and costly due to complex lattice designs requiring extensive welding, limited access for painting, and excessive height for sufficient flexural and torsional strength, leading to inefficiencies and increased noise from vibrations.
Innovation Solution
A turbomachine base plate comprising an upper and lower metal plate with an intermediate layer of unfoamed polymer, polymer foam, metal foam, or ceramic foam between them, bonded to a peripheral frame, eliminating the need for welding and reducing weight and noise through improved structural integrity and vibration damping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a lattice structure is used to provide sufficient flexural and torsional strength, then the mechanical strength is improved, but the height of the base plate becomes substantial (600-700 mm), making it cumbersome and heavy to transport
Solution Approach 1:
The patent uses a composite sandwich structure consisting of two metal plates (steel or aluminum) bonded to a polyurethane foam core. This composite construction provides high flexural and torsional strength comparable to traditional lattice structures, but with a reduced height of only 200-300 mm. The foam core contributes to the overall structural rigidity while keeping the base plate compact and easier to transport.
Solution Approach 2:
The metal plates are bonded to the foam core using adhesive layers, creating a thin-film composite structure. This approach allows the base plate to achieve sufficient mechanical strength with reduced thickness compared to rigid lattice structures, as the bonded thin metal layers work together with the foam core to resist bending and twisting forces.
2Force
If a lattice structure is used to support rotary machines, then the load capability is improved, but the structure requires extensive welding of beams, making the manufacturing process labor-intensive and expensive
Solution Approach 1:
The patent extracts the welding operation from the manufacturing process by replacing the lattice structure with a sandwich structure. The metal plates are bonded to the foam core using adhesive instead of welding beams together, eliminating the need for complex welding operations and significantly simplifying the manufacturing process while maintaining load capability.
Solution Approach 2:
The patent replaces the mechanical welding system with a chemical bonding system. Instead of joining metal beams through welding, the metal plates are bonded to the foam core using adhesive, substituting a complex mechanical joining process with a simpler chemical bonding process that reduces labor intensity and manufacturing cost.
3Strength
If a lattice structure is used to provide structural support, then the strength is improved, but the complexity of the structure and large number of beams make the painting operation labor intensive and time consuming
Solution Approach 1:
The sandwich structure uses a solid foam core between two metal plates, creating a simple composite form that requires minimal painting compared to the complex lattice structure. The foam core is already protected by the metal plates, and only the external surfaces of the metal plates and frame need to be painted, significantly reducing the painting operation's complexity and time requirements.
4Strength
If the height of the lattice structure is increased to provide sufficient flexural and torsional strength, then the mechanical performance is improved, but the base plate becomes expensive and heavy to transport
Solution Approach 1:
The patent uses a composite sandwich structure with metal plates bonded to a foam core, achieving high flexural and torsional strength with a compact height of 200-300 mm. This design reduces the weight compared to a 600-700 mm tall lattice structure while maintaining mechanical performance, making the base plate easier and less expensive to transport.
Solution Approach 2:
The foam core acts as a lightweight material that provides structural support without adding excessive weight. By using the foam as the central core and bonding metal plates to it, the structure achieves the necessary strength-to-weight ratio, counterbalancing the need for height while minimizing overall weight.
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 lighter, easier-to-manufacture base plate with enhanced mechanical strength and reduced noise, achieving comparable flexural and torsional performance to traditional lattice structures with a lower profile and reduced material costs.
Implementation Method 1
Plates are subject to vibrations induced by the operation of the gas turbine engine, and/or possible other rotating machines mounted on the base plate. This generates noise. Noise damping equipment is requested around the base plate and the gas turbine engine enclosure.
Implementation Method 2
An intermediate layer made of a filling material, being selected from the group comprising: an unfoamed polymer, a polymer foam, a metal foam, a ceramic foam, or combination thereof, is arranged between the upper plate and the lower plate and is bonded to the inner surfaces of the upper and lower metal plates
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A turbomachine base plate 3 is disclosed. The base pate comprises an upper metal plate 17 and a lower metal plate 19. The upper metal plate 17 forms a turbomachine supporting surface 3T. The base plate further includes an intermediate layer 27 between the upper metal plate 17 and the lower metal plate 19 and bonded thereto. A frame 21 extends peripherally around the intermediate layer 27.