Composite Containment Case for Fan Blade Impact and Puncture Resistance
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Solution Overview
Problem
Conventional containment cases for gas turbine engines are heavy due to solid metal construction and lack effective impact resistance, particularly against fan blade detachment or failure, which can cause damage to the aircraft, while composite materials are susceptible to puncture from sharp objects.
Innovation Solution
A composite core containment case with integrated puncture-resistant and energy-capture layers, where the puncture-resistant layer provides high through-thickness shear strength and interlaminar toughness, and the energy-capture layer offers high in-plane tensile strength with low delamination resistance, bonded with resin to the inner and outer surfaces respectively, optimizing impact resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional solid metal containment cases are used, then impact resistance and containment capability are improved, but weight increases significantly
Solution Approach 1:
The patent applies composite materials by combining a metal containment case with multiple layers including a puncture resistant layer, an energy capture layer, and a metal reinforcement layer. This composite structure provides enhanced impact resistance and containment capability while reducing the overall weight compared to solid metal construction of equivalent thickness.
Solution Approach 2:
The containment case is segmented into distinct functional layers: a puncture resistant layer (e.g., ceramic or composite material) to prevent penetration, an energy capture layer (e.g., foam or honeycomb structure) to absorb impact energy, and a metal reinforcement layer for structural integrity. Each layer performs a specific function, optimizing the overall performance while minimizing weight.
2Weight of stationary object
If composite materials are used for containment cases, then weight is reduced, but puncture resistance from sharp objects deteriorates
Solution Approach 1:
The patent uses a composite structure where a puncture resistant layer made of ceramic or composite material is applied to the interior surface of the metal containment case. This layer specifically addresses the puncture resistance issue while the overall composite structure maintains weight advantages over solid metal construction.
Solution Approach 2:
The puncture resistant layer is applied specifically to the interior surface where impact and puncture risks are highest, rather than making the entire containment case uniformly thick and heavy. This localized application provides targeted protection while minimizing overall weight increase.
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 enhanced impact resistance and weight savings compared to conventional metallic cases, effectively containing fan blades and preventing damage to the engine, while maintaining structural integrity and reducing the risk of puncture and delamination.
Implementation Method 1
The at least one puncture resistant layer is integrated with the composite core and includes a resin to bond the at least one puncture resistant layer to the inner surface of the composite core
Implementation Method 2
The at least one energy capture layer is integrated with the composite core and includes a resin to bond the at least one energy capture layer to the outer surface of the composite core
Implementation Method 3
The at least one puncture resistant layer is characterized by a high through-thickness shear strength and a high interlaminar toughness at impact
Implementation Method 4
The at least one energy capture layer is characterized by a high in-plane tensile strength and low resistance to delamination and fiber-matrix debonding at impact
Data Source
AI summary
A containment case comprises a composite core, with an inner and outer surface, at least one puncture resistant layer bonded to the inner surface of the composite core and at least one energy capture layer bonded to the outer surface of the composite core. The puncture resistant layer having a high through-thickness shear strength and high interlaminar toughness at impact. The energy capture layer having a high in-plane tensile strength and low resistance to delamination and fiber-matrix debonding at impact. A method of fabricating a containment case includes the steps of disposing one or more layers of a puncture resistant material on a layup mandrel, disposing one more layers of a structural composite material on an exterior surface of the puncture resistant material, disposing one or more layers of an energy capture material on an exterior surface of the structural material and curing a resin in the plurality of layers.