Composite Blade Impact Resistance via Elastic Polymer Covering
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Solution Overview
Problem
Carbon fiber reinforced plastic (CFRP) blades lack sufficient impact resistance for applications in aircraft engines and industrial gas turbines, particularly against bird strikes and ice collisions, and the addition of metal sheaths increases weight, reducing the fuel efficiency benefits of CFRP.
Innovation Solution
A composite blade design featuring a preform portion made of carbon fiber reinforced plastic and an outer covering unit of elastic polymer fiber reinforced resin, which enhances impact resistance by using aramid, polyarylate-based, or liquid crystal fully aromatic polyester fibers, and a neutral or cushioning unit to absorb and attenuate impact energy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal sheath-shaped member is adhered to cover the leading edge and tip portion of the fan blade to improve impact resistance, then impact resistance is improved, but weight increases
Solution Approach 1:
The patent changes the material parameter from metal to elastic polymer fiber reinforced resin, which has different mechanical properties including comparable impact resistance but lower density. This material substitution resolves the contradiction by maintaining protective function while reducing weight.
Solution Approach 2:
The patent uses composite materials by combining carbon fiber reinforced plastic for the preform portion with elastic polymer fiber reinforced resin for the covering unit. This creates a hybrid structure that leverages the high strength of carbon fiber and the high impact resistance of elastic polymer fibers, achieving both weight reduction and improved impact resistance.
2Weight of moving object
If CFRP is applied to the fan blade to reduce weight and improve fuel efficiency, then weight is reduced and fuel efficiency is improved, but impact resistance against bird strike collisions is insufficient
Solution Approach 1:
The patent applies local quality by providing the first covering unit made of elastic polymer fiber reinforced resin specifically at the leading edge and tip portions where impact resistance is most needed. The preform portion uses CFRP for weight reduction, while the covering unit provides localized impact protection where foreign object strikes are most likely to occur.
3Strength
If metal is used for the protective member to improve impact resistance, then impact resistance is improved, but the weight reduction effect of CFRP cannot be fully exhibited
Solution Approach 1:
The patent changes the material parameter from metal to elastic polymer fiber reinforced resin, substituting a material with high density and high impact resistance with one that has lower density but comparable or superior impact resistance due to the elastic properties of the polymer fibers. This resolves the contradiction by achieving impact protection without the weight penalty of metal.
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 composite blade achieves improved impact resistance without increasing weight, effectively protecting against foreign object collisions and maintaining the weight reduction benefits of CFRP, while also reducing the risk of damage from ice or bird strikes.
Implementation Method 1
the first covering unit is formed of an elastic polymer fiber reinforced resin containing elastic polymer fibers and a second resin, and has more impact resistance than the preform portion
Data Source
AI summary
This composite-material blade formed by using a fiber-reinforced resin containing a resin and reinforcing fibers is provided with: a base material part provided on the inner surface of the composite-material blade; and a first cover part for covering the outer surface of the base material part. The base material part is formed by using a carbon fiber-reinforced resin containing a first resin and carbon fibers. The first cover part is formed from an elastic polymer fiber-reinforced resin containing a second resin and elastic polymer fibers, and has more resistance to impact than the base material part.