Composite Spar Airfoil Assembly with Lobe-Sleeve Interlock
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Solution Overview
Problem
Traditional airfoil assemblies in turbine engines face challenges in maintaining mechanical integrity and extending the lifetime of components due to the use of metal spars, which can be prone to stress and wear, especially in high-temperature environments.
Innovation Solution
The use of a composite spar with a set of lobes that interlock with recesses in a metal sleeve, providing improved coupling and torque transfer, while utilizing materials like polymer matrix composites and ceramic matrix composites for enhanced durability and resistance to mechanical stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal spars are used in traditional airfoil assemblies, then structural strength is provided, but mechanical integrity deteriorates due to stress and wear in high-temperature environments
Solution Approach 1:
The patent applies composite materials by replacing traditional metal spars with composite spars that combine multiple materials (e.g., carbon fiber reinforced polymers, ceramic matrix composites) to achieve both high strength and resistance to thermal stress and wear. The composite spar includes a core structure surrounded by a composite material layer, providing enhanced mechanical integrity while maintaining structural strength in high-temperature turbine engine environments.
2Strength
If composite spars are used to improve durability, then resistance to warping and bending improves, but coupling strength with metal sleeve deteriorates
Solution Approach 1:
The patent applies the nesting principle by placing the composite spar inside a metal sleeve structure, where the composite spar is surrounded and supported by the metallic sleeve. This nested configuration allows the composite material to provide resistance to warping and bending while the metal sleeve provides enhanced coupling strength and torque transfer capability, resolving the contradiction between durability and coupling strength.
Solution Approach 2:
The patent uses composite materials for the spar structure to achieve superior resistance to warping and bending compared to traditional metal spars. The composite material layer surrounding the core provides high stiffness and strength-to-weight ratio, while the overall assembly with the metal sleeve maintains adequate coupling strength through the nested configuration.
3Force
If traditional metal spars are used, then torque transfer is adequate, but lifetime of components deteriorates due to wear and stress
Solution Approach 1:
The patent applies composite materials to replace traditional metal spars with composite spars that have superior resistance to wear and thermal stress. The composite material composition (e.g., carbon fiber reinforced polymers, ceramic matrix composites) provides enhanced durability and extended component lifetime while maintaining adequate torque transfer capability through proper structural design and interface configuration with the metal sleeve.
Data Source
AI summary
An airfoil assembly for a turbine engine having a composite spar, a sleeve, and a set of lobes. The composite spar includes an exterior spar portion, where at least part of the exterior spar portion of the composite spar is received at a sleeve inner surface of the sleeve. The set of lobes extends from the composite spar and is received by a set of recesses at the sleeve inner surface.