Composite Aerofoil Vane Torsional Stiffness via Interlaced Fibres

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Solution Overview

Problem

Current fibre-reinforced composite vanes for gas turbine engines face challenges in resisting torsional vibration and structural loads, leading to increased thickness and weight compared to metal vanes, which negatively impacts aerodynamic performance.

Innovation Solution

A composite aerofoil vane design featuring unidirectional fibre bundles and interlaced axial/circumferential fibres, providing improved torsional stiffness and structural integrity while minimizing thickness and weight penalties, achieved through a more integrated fibre structure and optimized fibre arrangement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If composite material is used for OGVs to reduce weight, then weight is reduced, but torsional stiffness and structural integrity are insufficient requiring increased thickness

Engineering Contradiction:

Improvevane weightVSAvoidtorsional stiffness

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent uses fibre-reinforced composite materials (such as carbon fibre reinforced polymer) to construct the OGV, achieving weight reduction while maintaining structural integrity through the high strength-to-weight ratio of the composite material

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent introduces a novel three-dimensional fibre arrangement where fibres are oriented in multiple directions (radial, tangential, and longitudinal) to create an integrated reinforcement structure that provides torsional stiffness without increasing thickness

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Weight of moving object

If composite material is used for OGVs to reduce weight, then weight is reduced, but aerodynamic performance deteriorates due to increased thickness

Engineering Contradiction:

Improvevane weightVSAvoidaerodynamic performance

Core Design Contradiction:

Weight of moving objectVSProductivity

Solution Approach 1:

The patent applies different fibre orientations and densities to different regions of the OGV, concentrating reinforcement where structurally necessary while maintaining thinner sections where aerodynamic performance is critical, thus optimizing the balance between weight reduction and aerodynamic efficiency

Inventive Principle:

Principle #3Local quality

3Ease of manufacture

If traditional composite vane design is used, then manufacturing is simpler, but mechanical properties and structural integrity are insufficient

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidstructural integrity

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent employs preliminary fibre placement and orientation techniques during the manufacturing process to pre-position reinforcement fibres in optimal locations before molding, ensuring high structural integrity is built into the component during fabrication rather than requiring post-processing

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS9670788B2Composite aerofoil vane

Publication Date: 2017.06.06 ROLLS ROYCE PLC

AI summary

A composite aerofoil vane for a gas turbine engine extends in use in a generally radial direction across an axially- and circumferentially-extending annular duct. The vane comprises a plurality of first reinforcing fibers extending in a generally radial direction and a plurality of second reinforcing fibers extending in generally axial and circumferential directions. The second fibers are interlaced with the first fibers so as to form a more unified and integrated structure, and to prevent the first reinforcing fibers from moving relative to one another.