Gas Turbine Composite Part with In-Service Cured Thermal Shield

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Solution Overview

Problem

Composite materials for gas turbine engines have a low operating temperature limit, making them unsuitable for hotter sections unless thermally protected, which can be expensive and weight-intensive, and prevents inspection of the underlying material.

Innovation Solution

A method involving a composite part with a first material having a low operating temperature limit and a second material with a higher limit, where the second material is cured by engine heat to thermally shield the first material, eliminating the need for external thermal protection and allowing inspection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If composite material is used in hotter sections of the engine, then the operating temperature range is extended, but the composite material requires additional thermal protection

Engineering Contradiction:

Improveoperating temperature rangeVSAvoidthermal protection structure

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent combines the thermal protection function with the structural composite material by integrating a thermal barrier coating directly onto the composite substrate, creating a unified component that performs both structural and thermal protection functions simultaneously

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent uses a composite structure consisting of a base composite material layer and a thermal barrier coating layer, where each layer contributes different properties (structural integrity and thermal protection) to create a multi-functional component suitable for high-temperature engine sections

Inventive Principle:

Principle #40Composite materials

2Temperature

If thermal protection is applied to the composite material, then the composite material can withstand higher temperatures, but inspection of the underlying composite material is prevented

Engineering Contradiction:

Improvetemperature resistanceVSAvoidinspection accessibility

Core Design Contradiction:

TemperatureVSDifficulty of detecting and measuring

Solution Approach 1:

The thermal barrier coating is applied selectively to specific areas of the composite material where thermal protection is most needed, rather than covering the entire surface, allowing inspection of critical areas while providing protection where required

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The thermal protection system is divided into discrete, localized protection zones rather than a continuous covering, enabling selective inspection of unprotected areas while maintaining thermal protection in high-heat zones

Inventive Principle:

Principle #1Segmentation

3Temperature

If thermal protection is integrated to the composite material, then the composite material can operate in hotter sections, but weight penalty is imposed

Engineering Contradiction:

Improveoperating temperature capabilityVSAvoidcomponent weight

Core Design Contradiction:

TemperatureVSWeight of moving object

Solution Approach 1:

The thermal barrier is implemented as a thin coating layer rather than a thick protective shell, providing necessary thermal protection while minimizing additional weight through the use of thin-film deposition techniques

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The thermal protection system uses materials with optimized thermal conductivity parameters and controlled coating thickness to achieve the required thermal barrier performance with minimal mass addition

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

Enables the use of composite materials in higher temperature applications without additional thermal protection, reducing weight and complexity, and facilitating inspection by integrating thermal shielding within the composite structure.

Implementation Method 1

the second composite material defining the outer surface of the composite part is cured by exposure to the heat generated from operation of the engine

Methodology Applied

Scientific EffectHeat: Heating

Implementation Method 2

the second composite material thermally shielding the first composite material from the heat generated from operation of the engine

Methodology Applied

Scientific EffectThermal shielding: Thermal Insulation

Data Source

PatentUS11002148B2Method for forming a composite part of a gas turbine engine

Publication Date: 2021.05.11 PRATT & WHITNEY CANADA CORP

AI summary

A method for forming a composite part of a gas turbine engine. The method includes assembling the composite part of a first composite material and a second composite material. The second composite material defines an outer surface of the composite part, and is selected to be curable at a cure temperature generated by heat from operation of the engine. The first composite material is selected to have an operating temperature limit less than the cure temperature. The method includes placing the composite part within the engine so that, in use, the second composite material is cured by exposure to the heat generated from operation of the engine. The second composite material thermally shields the first composite material from the heat generated from operation of the engine. The method includes operating the engine to cure the second composite material.