Hybrid Metallic-Composite Fairings for Power Generation Machines

Solution Overview

Problem

Existing fairings for power generation machines fail to effectively minimize drag and provide fire containment while meeting international standards, leading to suboptimal aerodynamic performance and increased weight.

Innovation Solution

A fairing comprising a metallic first layer for coupling to the power generation machine, configured to comply with ISO2685:1998 for fire containment, and a composite second layer with a convex external surface to minimize protrusions and reduce drag, using materials like aluminium, titanium, or steel for the first layer and carbon composite or oxide ceramic matrix composite for the second layer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a single-layer metallic fairing is used to ensure fire containment, then fire protection is improved, but weight increases and aerodynamic performance deteriorates

Engineering Contradiction:

Improvefire containmentVSAvoidfairing mass

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The fairing is divided into two distinct layers: a metallic first layer (0.5-2mm thickness) providing fire containment, and a composite second layer (2-5mm thickness) providing aerodynamic optimization. This segmentation allows each layer to specialize in its function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The fairing combines metallic material (aluminum, steel, or titanium) with composite material (carbon fiber reinforced polymer or ceramic matrix composite) to create a hybrid structure that leverages the fire resistance of metal and the lightweight aerodynamic properties of composites.

Inventive Principle:

Principle #40Composite materials

2Strength

If a single-layer metallic fairing is used to ensure structural integrity, then strength is improved, but drag increases due to surface protrusions

Engineering Contradiction:

Improvestructural integrityVSAvoidaerodynamic drag

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The fairing is divided into two distinct layers: a metallic first layer (0.5-2mm thickness) providing fire containment, and a composite second layer (2-5mm thickness) providing aerodynamic optimization. This segmentation allows each layer to specialize in its function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The fairing combines metallic material (aluminum, steel, or titanium) with composite material (carbon fiber reinforced polymer or ceramic matrix composite) to create a hybrid structure that leverages the fire resistance of metal and the lightweight aerodynamic properties of composites.

Inventive Principle:

Principle #40Composite materials

3Reliability

If a thick metallic fairing is used to provide fire containment, then fire protection is improved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvefire containmentVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The fairing is divided into two distinct layers: a metallic first layer (0.5-2mm thickness) providing fire containment, and a composite second layer (2-5mm thickness) providing aerodynamic optimization. This segmentation allows each layer to be manufactured independently using optimal processes for each material type.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The fairing combines metallic material (aluminum, steel, or titanium) with composite material (carbon fiber reinforced polymer or ceramic matrix composite) to create a hybrid structure that leverages the fire resistance of metal and the lightweight aerodynamic properties of composites.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS11339684B2Fairings for power generation machines

Publication Date: 2022.05.24 ROLLS ROYCE PLC

AI summary

A fairing for a power generation machine, the fairing comprising: a first layer comprising a metallic material and defining a first surface and a second opposite surface, the first layer being configured to enable the fairing to be coupled to the power generation machine; and a second layer comprising a composite material and defining a first surface and a second opposite surface, the second layer being coupled to the first layer, the second surface of the second layer defining an external surface of the fairing.