Composite Vane Leading Edge Sheath Bonding
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Solution Overview
Problem
The challenge lies in precisely attaching a metal sheath to the leading edge section of a composite vane in turbofan engines using a soft adhesive, where maintaining uniform thickness is difficult, leading to inefficiencies in both damage protection and replacement processes.
Innovation Solution
The composite vane incorporates an adhesive filling section with leading edge side contact sections and vane surface side contact sections of uniform height, ensuring precise attachment of the metal sheath by matching the adhesive thickness, facilitating easier and more precise bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a soft adhesive is used to bond the metal sheath to the leading edge section, then damage from foreign objects is suppressed and replacement is facilitated, but it is difficult to maintain uniform adhesive thickness
Solution Approach 1:
The patent applies preliminary action by pre-forming protrusions on the leading edge section before bonding the metal sheath. These protrusions are created during the composite material molding process, establishing the adhesive thickness control features in advance. This allows the adhesive layer thickness to be predetermined and uniform, resolving the difficulty of maintaining consistent thickness while using soft adhesive for damage protection.
Solution Approach 2:
The patent changes the physical state and properties of the adhesive by specifying it as a soft adhesive with controlled viscosity and curing characteristics. The adhesive is applied in a soft, moldable state that allows it to conform to the protrusions, ensuring uniform thickness. After bonding, the adhesive cures to provide the necessary strength while maintaining the thickness control established by the protrusions.
2Measurement precision
If studs are formed on the surface to control adhesive thickness, then positioning is improved, but the process becomes more complex and time-consuming
Solution Approach 1:
The patent merges the adhesive thickness control function with the structural features of the leading edge section itself. The protrusions are integrated into the leading edge section as a single component, eliminating the need for separate studs or positioning fixtures. This consolidation simplifies the overall process while maintaining precise positioning and thickness control capabilities.
Solution Approach 2:
The leading edge section serves its own positioning and thickness control function through the integrated protrusions, eliminating the need for external positioning devices or complex alignment procedures. The protrusions are self-contained features that automatically establish the correct adhesive layer thickness and metal sheath positioning during the bonding process.
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 effectively reduces damage from foreign objects, simplifies the replacement process, and ensures high-precision attachment of the metal sheath, enhancing both protection and maintenance efficiency.
Implementation Method 1
a metal sheath that is bonded to a leading edge section (a leading edge and a vicinity of the leading edge) of the composite vane body via a soft adhesive
Data Source
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AI summary
A composite vane body 11 formed of a composite material of a thermosetting resin or a thermoplastic resin, and reinforced fibers, and a metal sheath 12 that is bonded to a leading edge section 11A of the composite vane body 11 via a soft adhesive 13 to cover the leading edge section 11A are included, and an adhesive filling section 11a in which the soft adhesive 13 is filled, a plurality of leading edge side contact sections 11b that come into contact with a curved section 12b corresponding to a leading edge of the metal sheath 12, and a plurality of protrusions 11c that come into contact with a planar section 12c corresponding to a vane surface of the metal sheath 12, with at least a same height as a thickness of a layer of a requisite amount of the soft adhesive 13 filled in the adhesive filling section 11a are formed in the leading edge section 11A of the composite vane body 11. Attachment of the metal sheath to the leading edge section can be performed easily with high precision.