Composite Fan Containment Case with Reinforcing Ribs
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Solution Overview
Problem
Traditional fan containment cases in gas turbine engines are heavy due to their metallic construction, which is a concern for large fan sections, and they lack efficient structural support near the fan blade tips, making them inadequate for containing separated blade portions effectively.
Innovation Solution
A composite fan containment case is designed using first and second composite layers with axially spaced rings forming reinforcing ribs, a belt spanning the containment area, and a rub-resistant surface on the inner layer, eliminating intermediate structural support between the fan blade tips and the inner layer, constructed from materials like carbon fibers and epoxy with specific orientations and structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metallic inner liner is used in the fan containment case, then the structural strength and containment capability are improved, but the weight of the fan containment case increases significantly
Solution Approach 1:
The patent applies composite materials by combining a metallic inner liner with an outer shell structure that may include composite materials. This composite construction allows the containment case to maintain the high strength and containment capability of metal while reducing overall weight through the use of lighter composite materials in the outer structure, directly resolving the contradiction between strength and weight.
2Stability of the object's composition
If intermediate structural support is added between the fan blade tips and the inner layer, then the structural rigidity is improved, but the device complexity and weight increase
Solution Approach 1:
The patent applies local quality by providing structural support specifically at the blade tip region where it is most needed for containment, rather than adding uniform support throughout the entire structure. The inner liner is positioned in close proximity to the blade tips with minimal spacing, providing localized rigidity and containment capability where required, while avoiding unnecessary complexity in other regions of the fan containment case.
Data Source
Figure 1~4
Figure 2~3
AI summary
A gas turbine engine fan section includes first and second composite layers (32,34,36) providing a generally cylindrical case. Axially spaced apart rings (46) are arranged between the first and second composite layers and form reinforcing ribs (44) that provide a fan containment area (56) axially between the rings (46). A belt (50) is arranged over and spans the fan containment area (56) between the reinforcing ribs (44). A fan blade has a tip (29) in proximity to the first composite layer (32) without any intervening structural support between the tip (29) and the first composite layer (32), which provides a fan blade rub resistant surface. A method of manufacturing a fan containment case includes wrapping at least one first composite layer (32) around a mandrel. Axially spaced apart rings (46) are arranged circumferentially about the first composite layer (32). At least one second composite layer (36) is wrapped around the rings (46) and first composite layer (32) to provide reinforcing ribs (44) at the rings (46).