Fiber composite material and preform and fan blade made therefrom
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Solution Overview
Problem
Fiber composite fan blades for gas turbine engines have low strain tolerance, requiring increased thickness to withstand bird strikes and debris impact, which reduces efficiency and offsets weight savings, while existing materials are less ductile than metallic alloys.
Innovation Solution
A fiber composite material comprising a polymer matrix, carbon fibers, and non-carbon fibers with a higher strain to failure value than carbon fibers, combined in a woven structure, including aramid, polypropylene, or polyester fibers, to enhance ductility and resistance to impact damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If fiber composite fan blades are made thinner to maintain efficiency and weight savings, then fan efficiency and weight savings are improved, but strain tolerance and resistance to impact damage deteriorate
Solution Approach 1:
The patent applies composite materials by combining carbon fibers with high-strain non-carbon fibers (such as aramid, polypropylene, or polyester) in a polymer matrix. This multi-fiber composite structure enables the blade to achieve both high strength and high strain tolerance, allowing thinner designs that maintain efficiency while resisting impact damage from bird strikes and debris.
2Reliability
If fiber composite fan blades are made thicker to increase strain tolerance and resistance to impact, then strain tolerance and reliability are improved, but fan efficiency and weight savings deteriorate
Solution Approach 1:
The patent utilizes composite materials comprising carbon fibers combined with non-carbon fibers having higher strain to failure values. This composite structure provides enhanced strain tolerance and impact resistance without requiring increased blade thickness, thereby maintaining fan efficiency and preserving the weight savings advantage of composite materials over metallic alloys.
3Object-affected harmful factors
If fiber composite fan blades are made thicker to withstand bird strikes and debris impact, then resistance to impact damage is improved, but weight savings and efficiency deteriorate
Solution Approach 1:
The patent applies composite materials with a combination of carbon fibers and high-strain non-carbon fibers (aramid, polypropylene, polyester) in a polymer matrix. This composite structure provides superior impact resistance and strain tolerance, enabling the blade to withstand bird strikes and debris impact without increasing thickness or weight, thereby maintaining the weight savings advantage.
4Reliability
If the strain tolerance of fiber composite materials is increased through material composition, then ductility and energy absorption are improved, but manufacturing complexity may worsen
Solution Approach 1:
The patent applies composite materials by combining carbon fibers with non-carbon fibers in a polymer matrix. The fibers can be combined in various configurations including woven structures, random mats, or hybrid arrangements. While the material composition is complex, these composite structures can be manufactured using established composite manufacturing processes, balancing enhanced ductility and energy absorption with manufacturing feasibility.
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
The composite material improves ductility and energy absorption, providing greater resistance to bird strikes and small object impacts without compromising efficiency or weight savings, making it suitable for gas turbine engine fan blades.
Implementation Method 1
the non-carbon fibers have a strain to failure value greater than the strain to failure value of the carbon fibers
Data Source
AI summary
A fiber composite material comprises a polymer matrix, carbon fibers, and non-carbon fibers, wherein the non-carbon fibers have a strain to failure value greater than the strain to failure value of the carbon fibers. Also discussed is a preform comprising the fiber composite material combined in a three dimensionally woven structure. Also discussed is a fan blade for a jet engine.