Lap-Jointed Composite Flanges for Lightweight Circumferential Joints
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Solution Overview
Problem
Existing composite components in gas turbine engines face challenges in joining segments with circumferential flanges, leading to excess weight and complex geometries due to the use of metallic fasteners and plates, which complicates the replacement of legacy hardware with composites.
Innovation Solution
A lap jointed flanged composite component design featuring a butt joint and a lap joint with overlapping segments, allowing for composite components with both circumferential and longitudinal flanges, reducing the need for multiple fasteners and simplifying manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic fasteners and plates are used to join segments with circumferential flanges, then structural integrity is achieved, but weight increases excessively
Solution Approach 1:
The patent changes the material parameter from metallic to composite materials for the flanges and joining structure. The composite flanges maintain structural integrity while significantly reducing weight compared to traditional metallic fasteners and plates.
Solution Approach 2:
The patent employs composite materials for both the flanges and the joining structure. The composite-to-composite joining eliminates the need for heavy metallic fasteners and plates, achieving weight reduction while maintaining the required structural integrity through optimized composite layups and joining configurations.
2Reliability
If metallic hardware is used to join segments, then reliable connection is achieved, but device complexity increases due to complex composite geometries required
Solution Approach 1:
The patent applies homogeneity by using composite materials throughout the entire joining system - both the flanges and the joining structure are composite. This eliminates the need for complex hybrid metallic-composite geometries and simplifies the overall design while maintaining connection reliability.
Solution Approach 2:
The patent segments the joining structure into distinct composite components (flanges and joining sections) that can be manufactured separately and assembled. This segmentation simplifies manufacturing and reduces the complexity of creating monolithic complex geometries while ensuring reliable connections through standardized composite interfaces.
3Strength
If multiple fasteners and plates are used to join segments, then structural strength is maintained, but manufacturing complexity increases
Solution Approach 1:
The patent merges the functions of multiple separate metallic components (fasteners, plates, and flanges) into integrated composite structures. The composite flanges and joining sections are designed as unified structures that perform multiple functions simultaneously, significantly simplifying manufacturing compared to assembling multiple discrete metallic parts.
Solution Approach 2:
The patent replaces the traditional mechanical fastening system (multiple fasteners and plates) with a composite structural joining system. The composite materials and their inherent bonding mechanisms substitute for the complex mechanical assembly of multiple fasteners, reducing manufacturing complexity while maintaining joint strength.
Data Source
AI summary
A lap jointed flanged composite component including a first end opposite a second end with respect to an axis; a first segment coupled with a second segment to form the composite component; the first segment includes a first flange on at least one of the first end and the second end; the second segment includes a second flange on at least one of the first end and the second end; the first flange and the second flange being combined together at a butt joint forming a circumferential flange with respect to the axis; and a lap joint overlapping of the first segment with the second segment proximate the butt joint.