Composite Gearbox Housing With Passive Heat-Conducting Fillers

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Solution Overview

Problem

Conventional composite polymeric materials used in aircraft engine gearbox housings lack suitable thermodynamic characteristics for passive heat transfer due to reinforcing fibers being oriented for strength and stiffness rather than heat conduction.

Innovation Solution

A polymeric composite material reinforced with carbon fibers and thermally conductive fillers, such as carbon nano-fibers or carbon nanotubes, is used to facilitate passive heat conduction from the interior to the exterior surface of the gearbox housing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional composite polymeric materials with reinforcing fibers are used for strength and stiffness, then structural integrity is improved, but heat conduction capability deteriorates

Engineering Contradiction:

Improvestructural integrityVSAvoidheat conduction capability

Core Design Contradiction:

StrengthVSTemperature

Solution Approach 1:

The patent uses a composite material system consisting of polymeric matrix, reinforcing fibers (for strength), and thermally conductive filler particles (for heat conduction). This multi-component composite resolves the contradiction by combining materials with different functions: the polymeric matrix provides baseline structural integrity while the reinforcing fibers enhance strength and the thermally conductive filler particles create heat conduction pathways through the housing wall.

Inventive Principle:

Principle #40Composite materials

2Weight of moving object

If lightweight polymeric materials are substituted for metallic materials, then weight is reduced, but thermal conduction properties deteriorate

Engineering Contradiction:

Improvehousing weightVSAvoidthermal conduction properties

Core Design Contradiction:

Weight of moving objectVSTemperature

Solution Approach 1:

The patent changes the thermal parameters of the polymeric material by incorporating thermally conductive filler particles. This modifies the physical properties of the polymer composite to achieve thermal conduction capability comparable to or exceeding that of conventional metallic materials, while maintaining the weight advantage of polymeric materials.

Inventive Principle:

Principle #35Parameter changes

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

The solution effectively addresses the heat transfer issue by providing a lightweight, thermally conductive gearbox housing that prevents overheating, while maintaining structural integrity and reducing the risk of micro-cracking and fluid leakage.

Implementation Method 1

thermally conductive filler operable to passively conduct heat from a first side of the housing to the second side of the house

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

A polymeric composite material reinforced with carbon fibers and thermally conductive fillers, such as carbon nano-fibers or carbon nanotubes, is used to facilitate passive heat conduction

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentEP3196120B1Composite gearbox housing

Publication Date: 2023.05.24 GENERAL ELECTRIC CO

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AI summary

A housing (10) that includes a polymer (52), a reinforcing material (46, 48), and a thermally conductive filler (54). A first housing component (40) is defined by the polymer (52) such that the reinforcing material (46, 48) and a thermally conductive filler (54) are embedded within the polymer (52). The thermally conductive filler (54) is configured such that heat can be passively conducted through the first housing component (40). The housing (10) can be configured to be an aircraft gearbox housing.