Geared Turbofan Propulsor Blade Design
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Solution Overview
Problem
Gas turbine engines face inefficiencies due to high-speed fan operation causing flow discontinuities and turbulence, leading to irreversible propulsive losses, which are complex to mitigate in existing designs.
Innovation Solution
A geared turbofan architecture with propulsor blades made of carbon-fiber reinforced polymer matrix material, optimized with specific solidity values and geometry, and a variable area nozzle to reduce speed and enhance propulsive efficiency, along with a carbon-fiber reinforced polymer matrix material for the propulsor blades.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the fan rotates at high speed to propel the engine, then thrust is generated, but flow discontinuities and shocks occur causing irreversible propulsive losses
Solution Approach 1:
The patent applies parameter changes by optimizing the fan blade geometry parameters including airfoil shape, chord distribution, and twist angle along the span. These parameter modifications enable the blades to operate efficiently at high speeds while reducing flow discontinuities and shock-induced losses, thereby maintaining thrust generation while minimizing propulsive losses.
Solution Approach 2:
The patent employs dynamic design principles by incorporating variable geometry features such as twisted blade profiles and optimized chord distributions that adapt to different flow conditions along the blade span. This dynamic approach allows the blades to maintain optimal aerodynamic performance across varying operating conditions, reducing turbulence and energy losses while preserving thrust.
2Power
If physical interaction between the fan and air is increased to improve propulsion, then thrust is enhanced, but downstream turbulence increases causing further losses
Solution Approach 1:
The patent applies local quality by optimizing different sections of the fan blade with distinct geometric characteristics. The blade profile, chord length, and twist angle are locally tailored along the span to match the varying flow conditions, which enhances thrust generation in critical regions while minimizing turbulence generation in downstream areas through carefully designed local geometry modifications.
3Productivity
If the pressure ratio is increased to improve engine performance, then efficiency is enhanced, but the complexity of the design increases
Solution Approach 1:
The patent applies segmentation by dividing the compression function into multiple stages with intermediate cooling. This segmented approach achieves high overall pressure ratios and improved engine efficiency while keeping individual stage complexities manageable. The multi-stage compression system breaks down the complex high-pressure ratio requirement into several simpler, more manageable compression stages.
Data Source
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AI summary
A gas turbine engine (20) includes a core flow passage, a bypass flow passage, and a propulsor (42) arranged at an inlet of the bypass flow passage and the core flow passage. The propulsor (42) includes a row (72) of propulsor blades (74). The row (72) includes no more than 20 of the propulsor blades (74). The propulsor (42) has a pressure ratio between about 1.2 and about 1.7 across the propulsor blades (74).