Composite Vane Pocket Bonding With Reverse Adhesive Flow
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Solution Overview
Problem
Existing methods for joining vanes to supports, such as adhesive application and conventional injection molding, result in voids and uneven adhesive distribution, leading to reduced structural integrity and stress distribution issues.
Innovation Solution
A method involving reversing the flow of adhesive from an outlet towards an inlet, combined with pressure differentials and temperature control, to ensure complete filling of the adhesive in the vane-support joint, eliminating voids and optimizing the bond.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional injection molding techniques are used to bond the vane to the support, then the bonding process can be automated and productivity improved, but voids and air pockets form in the adhesive flow front reducing structural integrity
Solution Approach 1:
The patent applies reverse flow injection molding where the adhesive is injected from the outlet end towards the inlet end, opposite to the conventional direction. This inversion allows the adhesive to fill the cavity from the far end first, preventing air pockets from being trapped in the bond line and eliminating voids that would compromise structural integrity, while maintaining automated processing
2Ease of manufacture
If adhesive is injected through the cavity, then the bonding process is simplified, but the adhesive takes the route of least resistance resulting in uneven distribution and the vane not being held evenly
Solution Approach 1:
By reversing the injection direction from outlet to inlet, the adhesive flows against the natural path of least resistance and fills the cavity in reverse sequence. This ensures uniform distribution of adhesive across the bonding surface, preventing localized over-filling or under-filling and ensuring even holding force on the vane while maintaining process simplicity
3Manufacturing precision
If complex geometries and positioning of adhesive inlet and outlet are used, then complete filling of the cavity can be attempted, but areas around the inlet and outlet become difficult to fill with adhesive
Solution Approach 1:
The reverse flow approach allows the adhesive to enter from the outlet end and progress towards the inlet end, naturally filling difficult-to-reach areas first. This eliminates the problem of air pockets forming around the injection point and ensures complete cavity filling without requiring complex inlet/outlet positioning or additional manufacturing steps
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
Achieves an air-tight seal with uniform adhesive distribution, enhancing structural integrity and stress distribution, particularly suitable for gas turbine engines.
Implementation Method 1
causing an adhesive to flow between the vane and the support from an inlet to an outlet
Implementation Method 2
reversing the flow of adhesive from the outlet towards the inlet
Implementation Method 3
The temperature of the space may be increased before injecting the adhesive. This reduces the viscosity of the adhesive thus improving the flow of the adhesive through the space
Implementation Method 4
A differential pressure may be created between the inlet and outlet to cause the adhesive to flow into and through the space
Data Source
AI summary
A method of bonding a composite vane to at least one support. The method includes positioning an end of a vane within a support, causing an adhesive to flow between the vane and the support from an inlet to an outlet, and reversing the flow of adhesive from the outlet towards the inlet.