Composite Vane with Integrated Aerodynamic Covering Element
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Solution Overview
Problem
Existing flow straightener devices for turbomachines are heavy, complex to manufacture, and assemble, which negatively impacts turbomachine performance and efficiency.
Innovation Solution
A method for manufacturing composite material vanes using a covering element and a preform, where the covering element is attached to the platform via a hardened resin, simplifying the manufacturing process and reducing the weight of the vane by using a lighter material for the covering element, which is easier to modify and aerodynamically optimize.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional metal vanes are used for flow straightener devices, then mechanical strength and structural integrity are ensured, but the weight of the turbomachine components increases significantly
Solution Approach 1:
The patent applies composite materials by combining a preform (providing structural framework) with a covering element and resin matrix to create a vane that is both lightweight and mechanically strong. The composite structure allows optimization of both weight and strength properties that cannot be achieved with traditional metal alone.
2Productivity
If traditional manufacturing methods with separate platform and profile components are used, then structural integrity is maintained, but the manufacturing complexity and assembly time increase
Solution Approach 1:
The patent merges the platform and profile into a single integrated vane structure manufactured in one piece using composite material forming processes. This eliminates the need for separate manufacturing and assembly operations, significantly reducing manufacturing complexity and improving productivity.
3Adaptability or versatility
If a covering element is added to the platform for aerodynamic optimization, then the aerodynamic performance is improved, but the manufacturing complexity increases due to additional assembly steps
Solution Approach 1:
The covering element is integrated into the vane structure during the same manufacturing process rather than being assembled separately. This allows aerodynamic optimization to be achieved without increasing assembly complexity, as the covering becomes an inherent part of the monolithic composite vane.
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 method results in a lighter, easier-to-manufacture, and aerodynamically optimized composite material vane that reduces the mass and complexity of turbomachine components, allowing for simplified assembly and maintenance while maintaining mechanical integrity.
Implementation Method 1
injecting a first resin into the mold so that said resin impregnates and covers the preform and covers at least a portion of the covering element
Implementation Method 2
the covering element is attached to the platform by the first resin
Implementation Method 3
carrying out a heat treatment so as to harden the first resin
Data Source
AI summary
A method of manufacturing a composite material vane with a covering element, the vane including a platform and a profile extending perpendicularly to the platform, comprises the following steps: providing a covering element and a preform of the vane, the preform comprising a platform portion and a profile portion extending substantially perpendicularly to the platform portion; positioning the covering element against the platform portion so as to obtain an assembly; placing said assembly in a mold; injecting a first resin into the mold so that said resin impregnates and covers the preform and covers at least a portion of the covering element; and carrying out a heat treatment so as to harden the first resin.