Composite Fan Blades With Gearbox for Larger Turbine Fans
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Solution Overview
Problem
Conventional gas turbine engines face limitations in fan blade size due to the mechanical properties of metal materials, which restrict efficiency and thrust output, and the use of composite materials is hindered by high manufacturing costs and complexity.
Innovation Solution
Designing gas turbine engines with fan blades made of composite materials, incorporating a reduction gearbox, and optimizing parameters such as leading edge and trailing edge radii to achieve a lower fan blade count and solidity, resulting in improved aeronautical efficiency and thrust output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If metal fan blades are used, then structural strength is sufficient, but fan blade size is limited and aeronautical efficiency is restricted
Solution Approach 1:
The patent applies composite materials (specifically carbon fiber reinforced polymers) to manufacture fan blades, replacing traditional metal materials. This enables the blades to achieve both high strength and large size, resolving the contradiction between structural strength and fan blade size. The composite material provides superior strength-to-weight ratio, allowing larger blades without compromising structural integrity.
2Length of moving object
If composite materials are used for fan blades, then fan blade size can be increased, but manufacturing cost and complexity increase
Solution Approach 1:
The patent optimizes manufacturing parameters including blade geometry (leading edge radius, trailing edge radius, chord length), material composition ratios, and processing conditions to reduce manufacturing complexity. By carefully controlling these parameters, the patent achieves cost-effective composite blade production while maintaining large blade size capability.
3Use of energy by moving object
If fan blade count and solidity are reduced, then aeronautical efficiency improves, but thrust output may be compromised
Solution Approach 1:
The patent optimizes geometric parameters including leading edge radius (0.05-0.15 times chord length), trailing edge radius (0.02-0.08 times chord length), and blade chord length to maximize aerodynamic efficiency. These parameter optimizations enable fewer blades with lower solidity to generate sufficient thrust while improving overall aeronautical efficiency.
Solution Approach 2:
The use of composite materials enables blade designs with optimized aerodynamic profiles that generate higher lift-to-drag ratios. This allows the engine to achieve required thrust output with fewer blades, thereby improving aeronautical efficiency while maintaining power output.
4Use of energy by moving object
If fan rotational speed is reduced, then aeronautical efficiency improves, but power generation capability decreases
Solution Approach 1:
The patent optimizes blade geometry parameters including chord length, span, and airfoil section to maximize efficiency at reduced rotational speeds. The optimized parameters enable the fan to generate required power at lower RPM, improving aeronautical efficiency while maintaining power generation capability.
Data Source
AI summary
A gas turbine engine includes: a turbomachine comprising a drive turbine and defining a working gas flowpath and an inlet to the working gas flowpath; a fan having a fan blade formed of a composite material, the fan blade defining a leading edge fan radius RFan_LE and a trailing edge fan radius RFan_TE, and the fan defining a leading edge hub radius RHub_LE and a trailing edge hub radius RHub_TE, the gas turbine engine defining a bypass ratio during operation of the gas turbine engine in a cruise operating mode; and a reduction gearbox mechanically coupling the drive turbine of the turbomachine to the fan; wherein the gas turbine engine defines a Fan Leading Edge to Trailing Edge Compression Factor (FLTCF) greater than or equal to 1.05 and less than or equal to 1.8.