Ice Panel Segments for Turbofan Fan Cases
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Solution Overview
Problem
Ice accumulation on fan blades in turbofan engines poses a risk of damage to the fan case due to ice shedding at high speeds, and existing solutions require individually molded ice panel segments that are labor-intensive and costly to manufacture.
Innovation Solution
A method of manufacturing ice panel segments using a mandrel with a fibrous material like KEVLAR/epoxy and fiberglass layers, applied with tension to form a protective cylinder that is then cut into segments for bonding to the fan case, reducing the need for intermediate vacuum debulking and simplifying installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ice panel segments are individually molded to match the fan case geometry, then the protection effectiveness against ice impact is improved, but the manufacturing complexity and labor requirements increase
Solution Approach 1:
The ice panel is divided into multiple segments that can be manufactured separately using a simplified process and then assembled together to form the complete protective lining matching the fan case geometry
Solution Approach 2:
A mandrel is used as an intermediary tool to form the composite material into the desired cylindrical shape with integrated reinforcement structures, eliminating the need for complex direct molding of the final geometry
2Manufacturing precision
If intermediate vacuum debulking steps are included in the manufacturing process, then the manufacturing precision of ice panel segments is improved, but the productivity decreases
Solution Approach 1:
The reinforcement structures and geometric features are integrated into the mandrel design beforehand, so that when the composite material is wrapped and cured, the final precision geometry is achieved without requiring subsequent vacuum debulking or post-processing steps
3Strength
If multiple layers of composite material are wrapped around the mandrel, then the strength and durability of ice panel segments are improved, but the manufacturing time increases
Solution Approach 1:
Multiple layers of composite material are wrapped around the mandrel in continuous sequence without removal or repositioning, and the entire multi-layer structure is cured simultaneously in a single operation, reducing total manufacturing time while maintaining the strength benefits of multiple layers
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 method provides effective protection against ice impact while reducing manufacturing complexity and labor by using a composite material cylinder that can be efficiently cut into segments for installation, enhancing the durability and ease of production of ice panel segments.
Implementation Method 1
applying a plurality of layers of fibrous material and fiberglass around the mandrel with tension to form a molded cylinder
Data Source
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AI summary
The present disclosure relates to methods of manufacturing ice panel segments for turbofan engines. An ice panel material may be wrapped around a mandrel. The ice panel material may include an inner fiberglass layer, a plurality of KEVLAR® layers, and an outer fiberglass layer. The ice panel material may be bagged and cured into a rigid molded cylinder. The rigid molded cylinder may be radially cut into ice panel cylinders. The ice panel cylinders may be axially cut into ice panel segments. The ice panel segments may be bonded to an inner surface of a fan case.