Composite Blade Assembly via Chemical Bonding
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Solution Overview
Problem
Current turbomachine compressor rectifiers face challenges with composite material interfaces, particularly in terms of mass, cost, and differential expansion issues due to the use of metallic fixing means, which complicates assembly and maintenance.
Innovation Solution
The use of organic matrix composite parts with a thermoplastic or thermosetting matrix for the blades and housing, allowing for chemical or physico-chemical bonding and minimizing metallic fasteners, along with processes like compression molding, injection, and thermoforming for manufacturing, enables a lightweight, cost-effective, and easily assembled stator design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic fixing means are used to assemble composite parts, then mechanical strength is improved, but mass increases and differential expansion issues occur
Solution Approach 1:
The patent replaces metallic mechanical fastening systems with a chemical bonding system using polymeric adhesive. The composite part is bonded to the support structure through surface treatment (sandblasting, plasma treatment, or chemical etching) followed by adhesive application, eliminating the need for metallic fasteners and their associated weight and differential expansion problems.
Solution Approach 2:
The patent uses composite materials (fiber-reinforced polymers) for both the part to be fixed and the support structure, creating a homogeneous material system that bonds effectively through polymeric adhesive. This composite-to-composite bonding approach ensures compatible thermal expansion characteristics and eliminates the metal-composite interface problems.
2Strength
If metallic fixing means are used to assemble composite parts, then mechanical strength is improved, but device complexity increases due to numerous assembly issues
Solution Approach 1:
The patent replaces complex mechanical fastening systems (requiring alignment, torque control, and multiple fasteners) with a simplified adhesive bonding process. The surface treatment and adhesive application steps eliminate the need for precise mechanical alignment and complex fastener installation, significantly reducing assembly complexity.
3Weight of moving object
If composite materials are used for blades and housing, then mass is reduced, but manufacturing precision requirements increase for chemical bonding
Solution Approach 1:
The patent modifies surface parameters through treatment processes (sandblasting to create roughness, plasma treatment to increase surface energy, or chemical etching to create micropores) that enhance adhesive bonding without requiring extremely tight dimensional tolerances. These surface parameter changes enable reliable bonding while maintaining manufacturing feasibility.
4Strength
If hybrid metallic/composite assemblies are used, then structural performance is improved, but cost increases due to multiple material interfaces
Solution Approach 1:
The patent adopts a homogeneous composite-material architecture where both the blade/part and support structure are made from composite materials. This eliminates the hybrid metallic/composite interface, simplifying the manufacturing process and reducing costs associated with multi-material joining, while maintaining structural performance through optimized composite design.
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
This approach results in a low-mass, low-cost bladed stator with improved mechanical strength, simplified assembly and maintenance, reduced time for assembly, and reduced differential expansion issues, while maintaining structural rigidity and aerodynamic optimization.
Implementation Method 1
sealing means the operation of fixing a part in a support using a polymeric element charged or not by mechanical blocking and/or by physico-chemical interaction with the support and/or or the part to be fixed
Implementation Method 2
sealing means the operation of fixing a part in a support using a polymeric element charged or not by mechanical blocking and/or by physico-chemical interaction with the support and/or or the part to be fixed
Implementation Method 3
the housing with a thermosetting or thermoplastic CMO wall is manufactured by a process selected from the group consisting of compression molding, injection of a thermoplastic or thermosetting matrix, thermoforming and co-consolidation
Data Source
Figure 1~2
AI summary
The present invention relates to a mechanical assembly (1) comprising: - a part to be fixed (3) by one of its ends; - a housing with an organic matrix composite wall or CMO (2) intended to receive the part to be fixed (3); - an injected sealing composite (4) comprising a thermoplastic or thermosetting material filled between 0 and 70% by mass, creating a mechanical and/or physico-chemical bond between the part to be fixed (3) and the housing with an organic matrix composite wall (2).