I Beam Blade Platform Asymmetrical Composite Design
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Solution Overview
Problem
Current gas turbine engine fan blade platforms are costly to manufacture and require extended cure times, necessitating a need for lightweight, easily manufactured, and less expensive alternatives.
Innovation Solution
The use of an axially extending I beam with radially outer and inner I flanges and C beams made from non-metallic composite or thermoplastic materials, which are integral and monolithic, providing structural support while reducing weight through asymmetrical designs and weight relief holes, and bonded C beams for enhanced strength and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If resin transfer molding (RTM) method is used to manufacture fan blade platforms, then structural integrity can be maintained, but manufacturing cost increases and cure time extends
Solution Approach 1:
The patent changes the manufacturing method from RTM to a simpler molding process that uses a single pre-form instead of multiple pre-forms assembled in a mold. This parameter change in the manufacturing process reduces both cost and cure time while maintaining structural integrity through the simplified single-piece construction approach.
2Device complexity
If multiple pre-forms are assembled in a mold for RTM manufacturing, then structural complexity can be achieved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent applies segmentation by creating a single pre-form that is divided into distinct functional sections (platform portion and blade root portion) within one continuous piece. This single pre-form is then molded as one piece, eliminating the need to assemble multiple separate pre-forms while still achieving the required structural complexity through the integrated design.
Solution Approach 2:
The patent merges the platform portion and blade root portion into a single integrated pre-form structure. By combining these functions into one monolithic component that is molded as a single piece, the design eliminates the complexity of assembling multiple pre-forms while maintaining all necessary structural functions.
3Strength
If traditional platform designs are used, then structural support is provided, but weight increases
Solution Approach 1:
The patent uses composite materials for the pre-form construction, combining different materials to achieve optimal strength-to-weight ratio. The single pre-form is made from composite material that provides sufficient structural support for the platform while significantly reducing weight compared to traditional solid metal or homogeneous composite designs.
Data Source
AI summary
Fan blade platform includes axially extending I beam supporting radially outer skin having flowpath surface. I beam includes upper and lower or radially outer and inner I flanges on radially outer and inner beam ends of axially extending I web. Radially outer skin on top of and bonded or otherwise attached to radially outer I flange. I beam may be integral and monolithic and made from a non-metallic composite or thermoplastic material and have post cure formed weight relief holes. I beam may include oppositely facing or back to back first and second C beams. First C beam including axially extending first C web disposed between radially outer and inner first C flanges. Second C beam including axially extending second C web disposed between upper and lower or radially outer and inner second C flanges. I beam may be asymmetrical about center plane of I web.