Composite Flange Junctions Using Overlapping Metal Reinforcement Arms
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Solution Overview
Problem
Composite materials are not well suited for components with flange connections in gas turbine engines, leading to manufacturing complexity and potential loss of structural integrity, especially in aircraft applications where weight reduction is critical.
Innovation Solution
A metallic reinforcement plate with overlapping arms is used to connect composite component portions, allowing for stable flange connections by defining an angle between the arms and reducing thickness where they overlap, with options for bonding or mechanical fastening, and selecting materials with similar thermal expansion coefficients.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If composite materials are used to manufacture gas turbine engine components, then weight is reduced and engine performance is enhanced, but the ability to create stable flange connections is compromised
Solution Approach 1:
The invention uses a hybrid composite structure combining metallic reinforcement plates with composite component portions. The metallic plate provides structural integrity for flange connections while the composite portions maintain weight reduction benefits, creating a multi-material composite solution that resolves the contradiction between weight savings and connection stability.
Solution Approach 2:
The metallic reinforcement is applied locally only at flange connection areas rather than throughout the entire component. This localized reinforcement provides structural stability where needed while maintaining overall weight reduction, addressing the specific problem area without sacrificing the global benefit of composite material usage.
2Weight of moving object
If complex composite geometries are used to replace metallic hardware with flange connections, then weight reduction is achieved, but manufacturing complexity and structural uncertainty increase
Solution Approach 1:
The component is divided into separate portions: composite sections for weight-critical areas and a metallic reinforcement plate for connection-critical areas. This segmentation allows each part to be optimized independently, reducing overall manufacturing complexity while maintaining weight benefits.
Solution Approach 2:
The metallic reinforcement plate acts as an intermediary element between composite component portions, providing a familiar and well-understood connection interface. This intermediary simplifies the design process by using conventional metallic connection methods rather than requiring entirely new composite-to-composite joining techniques.
3Reliability
If thick composite sections are used at flange connection areas to maintain structural integrity, then connection stability is improved, but weight reduction benefits are lost
Solution Approach 1:
The hybrid metallic-composite construction allows the flange area to achieve metallic-level structural integrity without requiring increased thickness of the composite material itself. The metallic reinforcement plate provides the necessary strength while the composite portions remain thin and lightweight.
Solution Approach 2:
Structural reinforcement is concentrated locally at the flange connection area through the metallic plate, allowing the rest of the composite component to maintain reduced thickness. This localized quality enhancement provides structural integrity where needed without adding weight throughout the entire component.
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 solution provides a stable, lightweight connection that maintains structural integrity and simplifies manufacturing, reducing complexity and enhancing the durability of composite components in turbomachinery.
Implementation Method 1
at least one of the first arm and the second arm is bonded to at least one of the first composite component portion and the second composite component portion
Implementation Method 2
at least one of the first arm and the second arm is mechanically fastened to at least one of the first composite component portion and the second composite component portion
Implementation Method 3
composite material of the first and second composite component portions and metallic material of the metallic reinforcement plate are selected to have substantially the same coefficient of thermal expansion
Data Source
Figure 1~2
Figure 3~5
Figure 6~7
AI summary
A composite component for a gas turbine engine includes a first composite component portion (52); a second composite component portion (54); and a metallic reinforcement plate (50) connecting the first composite component portion (52) and the second composite component portion (54), wherein the metallic reinforcement plate (50) has a first arm (58) at least partially overlapping the first composite component portion (52), and a second arm (60) at least partially overlapping the second composite component portion (52).