Composite Flange Junctions Using Metallic Reinforcement Plates

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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 desired.

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, and can be bonded or mechanically fastened, with materials selected for matching thermal expansion coefficients.

Engineering Contradictions & Design Principles

VSEngineering 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 components are not well suited for flange connections to other components

Engineering Contradiction:

Improvecomponent weightVSAvoidflange connection manufacturing

Core Design Contradiction:

Weight of moving objectVSEase of manufacture

Solution Approach 1:

A metallic reinforcement plate is introduced as an intermediary component between composite component portions that require flange connections. The reinforcement plate provides a rigid structural element that can accommodate standard flange connection geometries, while the composite portions maintain their weight advantages. The reinforcement plate is bonded to the composite surfaces, creating a hybrid structure that combines the benefits of both material types.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Weight of moving object

If highly complex composite geometries are used to replace legacy metallic hardware with flange connections, then weight reduction is achieved, but manufacturing complexity and structural uncertainty increase

Engineering Contradiction:

Improvecomponent weightVSAvoidcomposite geometry complexity

Core Design Contradiction:

Weight of moving objectVSDevice complexity

Solution Approach 1:

The component is divided into distinct segments: composite component portions for weight-critical areas and a separate metallic reinforcement plate for connection-critical areas. This segmentation allows each portion to be optimized independently - the composite portions maintain simple, manufacturable geometries while the reinforcement plate handles the complex flange connection requirements. The segments are joined through bonding interfaces.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A hybrid composite structure is created by combining metallic reinforcement plate material with composite material portions. This composite materials approach allows the structure to leverage the high strength and stiffness of metal in connection areas while maintaining the weight advantages of composite materials in other areas, resolving the contradiction between weight reduction and connection complexity.

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If simple flange geometries are used in composite components, then manufacturing complexity is reduced, but the ability to accommodate legacy hardware interfaces is limited

Engineering Contradiction:

Improveflange geometry manufacturingVSAvoidhardware interface compatibility

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The metallic reinforcement plate serves multiple functions: it provides structural reinforcement, creates flange connection interfaces, and enables compatibility with legacy hardware standards. By concentrating these multi-functional requirements in the metallic portion rather than the composite portions, the overall design achieves both manufacturing simplicity and interface versatility.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 and durable connection that reduces manufacturing complexity and enhances structural integrity while maintaining weight reduction benefits of composite materials.

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

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Implementation Method 2

at least one of the first arm and the second arm is co-bonded to at least one of the first composite component portion and the second composite component portion

Methodology Applied

Scientific EffectCo-bonding: Chemical Bonding

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

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS20250389209A1Reinforcement plate flange junctions of composite components

Publication Date: 2025.12.25 RTX CORP

AI summary

A composite component for a gas turbine engine includes a first composite component portion; a second composite component portion; and a metallic reinforcement plate connecting the first composite component portion and the second composite component portion, wherein the metallic reinforcement plate has a first arm at least partially overlapping the first composite component portion, and a second arm at least partially overlapping the second composite component portion.