Composite Fan Casing Mold Flat Seal Design
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Solution Overview
Problem
Existing mold designs for manufacturing turbomachine fan casings from composite materials require significant handling time due to bolted T-shaped parts and suffer from rigidity issues at sector connections.
Innovation Solution
A mold design featuring a main axis mandrel with angular counter-mold sectors and flat seals between them, where each sector's sealing portion is oriented to compress the flat seal, enhancing rigidity and eliminating the need for T-shaped parts by direct fixation and elastomer seals for improved sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If T-shaped parts fixed by bolts are used to ensure sealing between angular sectors, then sealing is achieved, but handling time becomes very long due to screwing and unscrewing bolts
Solution Approach 1:
The patent removes the T-shaped parts and bolts from the sealing system, extracting the problematic fastening mechanism. Instead, flat seals are directly compressed between adjacent angular sectors without requiring any fastening elements, thereby eliminating the time-consuming bolt assembly and disassembly operations while maintaining sealing effectiveness.
Solution Approach 2:
The patent replaces the mechanical fastening system (bolts and T-shaped parts) with a direct compression sealing mechanism. The flat seals are compressed between the angular sectors through the mold closure force itself, substituting the complex bolted connection with a simpler friction-based compression seal that requires no assembly tools or fastening operations.
2Reliability
If T-shaped parts are used to connect angular sectors, then sealing is provided, but rigidity at the connection between sectors deteriorates
Solution Approach 1:
The patent extracts the T-shaped connection parts from the system, removing the source of rigidity problems. The direct compression between angular sectors through flat seals creates a more rigid connection than the bolted T-shaped parts, as the compression force distributes evenly across the seal interface without creating stress concentration points.
Solution Approach 2:
The patent employs flat seals made of elastomeric material that combines flexibility for sealing with sufficient structural integrity to maintain rigidity at the connection points. The elastomer compresses to fill gaps while maintaining a rigid seal interface that prevents deformation under injection pressure.
3Ease of manufacture
If multiple angular sectors are assembled around the mandrel, then the mold can close properly, but sealing between sectors becomes complex requiring T-shaped parts
Solution Approach 1:
The patent divides the mold into multiple angular sectors that can be independently assembled around the mandrel. Each sector is a separate component that can be positioned and secured independently, simplifying the assembly process. The flat seals are simple planar elements that fit between sectors without requiring complex T-shaped connection structures.
Solution Approach 2:
The patent replaces the complex mechanical T-shaped connection system with a simple compression-based sealing approach. The flat seals are compressed between adjacent angular sectors during mold closure, eliminating the need for T-shaped parts and their associated fastening mechanisms, thereby reducing overall device complexity while maintaining effective sealing.
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 design reduces handling time and improves rigidity, allowing for efficient and secure manufacturing of turbomachine fan casings with composite materials while maintaining effective sealing.
Implementation Method 1
a flat seal with a main axis of elongation directed along the main axis is arranged between each angular sector, said flat seal being compressed between two adjacent angular sectors
Implementation Method 2
A precursor material of the matrix is then injected into the mold in order to densify the fiber preform with said precursor material of the matrix. Once the fiber preform is densified, the precursor material is polymerized.
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to a mold (1) for manufacturing a turbine engine fan casing from a composite material, comprising: - a mandrel (2) which has a main axis (θ) and around which a fibrous fan casing preform is intended to be wound; - a plurality of angular sectors (3a, 3b) of a counter-mold which are assembled on the outer contour of the mandrel (2) and are intended to close the mold (1) and compact the fibrous preform wound around the mandrel (2); characterized in that a flat joint (5) which has a main elongation axis (β) oriented along the main axis (θ) is arranged between each angular sector (3a, 3b), said flat seal (5) being compressed between two adjacent angular sectors (3a, 3b), a first angular sector (3a) comprising a sealing portion (30a) extending underneath a lower face of the flat seal (5), while a second angular sector (3b) comprises a sealing portion (30b) extending on top of an upper face of the flat seal (5).