Gas Turbine Fan Blade Platform Bonded Composite Design
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Solution Overview
Problem
Existing gas turbine engines face challenges with weight and cost due to integral metal platforms and non-integral platforms secured to the fan hub, which add unnecessary weight and expense.
Innovation Solution
A bonded fan blade flowpath platform made from moldable materials such as carbon and glass reinforced thermosets or thermoplastics, using a two-piece design with interlocking mechanisms like pins and hooks, and a ridge retention system, which reduces weight and cost by eliminating the need for additional fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If integral metal platforms are used in the fan section, then structural strength is improved, but weight and manufacturing cost increase
Solution Approach 1:
The patent replaces traditional integral metal platforms with composite material platforms constructed from fiber-reinforced plastics (such as carbon fiber or glass fiber reinforced polymers). These composite platforms provide comparable structural strength to metal platforms while significantly reducing weight, directly resolving the contradiction between strength and weight.
Solution Approach 2:
The platform is divided into multiple segments or sections that can be separately manufactured and then assembled together. This segmentation allows for optimized material usage in each segment, reducing overall material consumption and weight while maintaining the required structural strength through strategic placement of reinforcement elements in each segment.
2Ease of manufacture
If non-integral platforms secured to fan hub are used, then ease of manufacture is improved, but weight and cost increase
Solution Approach 1:
The patent employs composite material platforms that are lighter than metal alternatives while maintaining manufacturability through modern composite manufacturing techniques such as autoclave curing, resin transfer molding, or automated fiber placement, thus achieving ease of manufacture without the weight penalty of traditional metal platforms.
Solution Approach 2:
The platform design integrates the platform structure with the fan blade or fan hub in a unified composite construction, eliminating the need for separate metal platforms and their associated fasteners. This merging reduces overall weight while simplifying the manufacturing process through integrated fabrication.
3Reliability
If integral metal platforms are used, then structural integrity is improved, but manufacturing cost increases
Solution Approach 1:
The patent utilizes composite material platforms that achieve required structural integrity through fiber reinforcement and optimized layup patterns, providing comparable or superior strength-to-weight ratio to metal platforms. The composite manufacturing process, while advanced, offers cost advantages by eliminating expensive metal machining, material waste, and assembly operations.
Solution Approach 2:
By segmenting the platform into modular composite sections, the patent enables parallel manufacturing of multiple segments, reducing overall manufacturing time and cost. Each segment can be manufactured independently using cost-effective composite techniques and then assembled with simplified joining methods, lowering total manufacturing cost while maintaining structural integrity.
4Ease of manufacture
If non-integral platforms are used, then ease of manufacture is improved, but device complexity increases
Solution Approach 1:
The patent merges the platform structure with the fan blade or hub into a unified design, eliminating the need for separate platform components and their associated fasteners and attachment mechanisms. This integration reduces device complexity while maintaining ease of manufacture through streamlined production processes.
Data Source
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AI summary
A fan (42) is provided. The fan (42) may comprise a fan blade (101) and a blade platform (102) coupled to the fan blade (101). The blade platform (102) may be a thermoplastic. A fan blade platform (102) is also provided. The fan blade platform (102) may comprise a first platform half (104) comprising a slot (114) at a first end of the first platform half (104) and a first receiving member (120) at a second end of the first platform half (104) opposite the first end of the first platform half (104). A second platform half (106) may comprise a hook (112). The second platform half (106) may also include a second receiving member (118) at a second end of the second platform half (106) opposite the first end of the second platform half (106) with the hook (112) configured to interface with the slot (114). A pin (116) may be configured to pass through the first receiving member (120) and the second receiving member (118).