Composite Vane Assembly with Flexible Attachment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing gas turbine engine vane assemblies face challenges in reducing weight and cost while maintaining performance under vibratory stresses, and existing manufacturing methods are inefficient in producing lightweight, cost-effective components resistant to high temperatures and pressures.
Innovation Solution
The use of composite materials such as carbon fiber reinforced epoxy resin for vane assemblies, combined with a flexible attachment system using a rubber potting material and an abradable surface, allows for reduced weight and cost while maintaining structural integrity and heat resistance, and a method of manufacturing that integrates outer shroud segments with vanes using injection or compression molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional materials (titanium, stainless steel, high grade aluminum) are used for vanes, then strength and heat resistance are maintained, but weight and manufacturing cost increase
Solution Approach 1:
The patent applies composite materials (carbon fiber reinforced epoxy resin) to manufacture the vane assembly, replacing traditional metals like titanium and aluminum. This composite material provides sufficient strength and heat resistance while significantly reducing weight, directly resolving the contradiction between weight reduction and strength maintenance
2Productivity
If traditional manufacturing methods are used, then structural integrity is ensured, but manufacturing efficiency and cost-effectiveness decrease
Solution Approach 1:
The patent merges multiple manufacturing operations into a single integrated process. The vane assembly is manufactured as a unified composite structure using injection or compression molding, eliminating the need for separate fabrication and assembly steps while maintaining manufacturing precision through mold-based production
3Reliability
If vanes are tuned for vibratory stress resistance, then durability under vibration is improved, but weight and complexity increase
Solution Approach 1:
The composite material structure inherently provides vibration damping properties due to its layered construction and material characteristics. The carbon fiber reinforcement provides structural strength while the epoxy matrix dampens vibratory stresses, achieving vibration resistance without additional weight from tuning mechanisms
Solution Approach 2:
The flexible attachment system using rubber potting material creates a compliant connection between the vane assembly and engine structure. This flexible mounting isolates the vane from harsh vibratory stresses while maintaining positional stability, improving reliability without requiring heavy reinforcement
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
This solution results in a lightweight, cost-effective vane assembly that reduces vibratory stresses and maintains performance under high temperatures and pressures, thereby enhancing the efficiency and durability of gas turbine engines.
Implementation Method 1
a flexible attachment system using a rubber potting material
Implementation Method 2
The vanes are subjected to vibratory stresses by the supporting structure and may be tuned according to the vibratory stress
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A vane assembly (104) may include a vane (108) comprised of a composite material. An outer shroud segment (160) may be disposed at radially outer end (122) of the vane (108). An inner shroud (140) may define an aperture (152). A radially inner end (124) of the vane (108) may be disposed within the aperture (152).