Fan Case Liner Assembly with Inductive Adhesive Curing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for attaching impact liners to gas turbine engine fan cases using film adhesives result in inadequate cure ramp rates, non-compliance with design requirements, high energy consumption, and increased costs due to the large size of the fan assembly, which can compromise the quality and durability of the impact liners.
Innovation Solution
A system utilizing an annular structure with a heat source to inductively heat an adhesive layer on the fan case barrel, coupled with a controller and temperature sensor to control the heating process, allowing for localized curing of the adhesive layer to bond liners to the inner surface, reducing the need for full-scale heating and minimizing energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional film adhesive curing is used in an autoclave or oven, then the adhesive layer can be cured, but the cure ramp rate is insufficient and energy consumption is high due to the large size of the fan assembly
Solution Approach 1:
The invention segments the curing process by applying localized heating only to the adhesive layer and immediate surrounding areas, rather than heating the entire fan assembly. The heating element is positioned to target specific zones where adhesive curing is needed, allowing independent control of curing conditions in different regions of the assembly.
Solution Approach 2:
The invention implements local quality by concentrating thermal energy specifically at the adhesive layer interface, creating a localized high-temperature zone for curing while leaving the rest of the fan assembly at lower temperatures. This selective heating approach enables adequate cure ramp rates for the adhesive while minimizing overall energy consumption.
2Reliability
If the entire fan case is heated in an autoclave or oven for adhesive curing, then the adhesive layer can be cured, but the curing time increases and manufacturing costs increase
Solution Approach 1:
The invention applies preliminary action by pre-positioning the heating element in contact with or adjacent to the adhesive layer before curing begins. This preliminary arrangement allows immediate localized heating once power is applied, eliminating the need to heat the entire assembly from ambient temperature and reducing overall curing time while maintaining bond quality.
Solution Approach 2:
The invention replaces the conventional mechanical/thermal system of autoclaving or oven heating with a direct electrical heating system. The heating element converts electrical energy directly into thermal energy at the precise location needed, eliminating the inefficiencies of heating large volumes of air and structural material, thereby reducing curing time and energy consumption.
3Strength
If conventional adhesive application methods are used, then liners can be attached to the fan case, but the adhesive bond strength is insufficient for protecting against blade detachment and foreign object impacts
Solution Approach 1:
The invention applies beforehand cushioning by incorporating a compression member that pre-compresses the adhesive layer during assembly. This compression ensures intimate contact between the adhesive and the fan case surface, eliminating voids and weak points, while the heating element subsequently cures the compressed adhesive to create a strong, impact-resistant bond.
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 approach enables faster curing cycles, lowers energy consumption, and achieves a desired cure ramp rate, resulting in improved adhesive bonds and enhanced durability of the liners, which protect the fan case from blade detachment and foreign object impacts, maintaining operational efficiency and safety of the gas turbine engine.
Implementation Method 1
a heat source coupled to the annular structure. The heat source is adapted to heat the annular structure to at least a predetermined curing temperature, such that the annular structure inductively heats the at least one adhesive layer
Data Source
AI summary
A system for assembling a fan case of a gas turbine engine includes at least one adhesive layer disposed on an inner surface of a fan case barrel, at least one liner disposed on the inwardly-facing surface of the at least one adhesive layer, an annular structure adapted to be disposed on an outer surface of the fan case barrel, and a heat source coupled to the annular structure to heat the annular structure to at least a predetermined curing temperature, such that the annular structure inductively heats the at least one adhesive layer. Upon being inductively heated by the annular structure, the at least one adhesive layer is cured, thereby adhesively bonding the at least one liner to the inner surface of the fan case barrel.