Integral Composite Stator Vane Ring Manufacturing
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Solution Overview
Problem
The manufacturing of complex composite products like stator vane rings for gas turbine engines involves high part counts and complexity, increasing costs due to individual component assembly and connection methods.
Innovation Solution
A method of manufacturing an integral thermoset or thermoplastic infused fibre reinforced composite stator vane ring by winding fibre reinforcement material around a mandrel to form inner and outer annulus preforms, arranging and connecting vane preforms using fibre jointing methods, and infusing thermoset or thermoplastic resin for curing, resulting in a monolithic structure capable of transferring structural loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If component parts are assembled and connected individually by bolting, then structural strength and load transfer are achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent merges multiple separate component parts (annulus sections and vane assemblies) into a single integral composite structure. The fibre reinforcement material is wound continuously to form all components as one monolithic preform, eliminating the need for separate bolting operations and reducing part count while maintaining structural load transfer capability
Solution Approach 2:
The patent uses fibre reinforcement material (such as carbon fibre or glass fibre) combined with resin to create a composite structure that provides both structural strength and aerodynamic functionality. The composite material allows for integration of multiple components into a single piece while maintaining the required mechanical properties for load transfer
2Reliability
If multiple component parts are assembled individually, then structural functionality is achieved, but part count and manufacturing cost increase
Solution Approach 1:
The patent combines multiple functional components (inner annulus, outer annulus, and vanes) into a single integral preform. The fibre reinforcement is wound to simultaneously create all these components as one piece, reducing the part count from multiple separate parts to a single integrated structure while preserving all structural functionalities
Solution Approach 2:
The single integral composite preform performs multiple functions simultaneously: it provides structural load transfer, defines aerodynamic flow paths, and creates the necessary geometric features for engine integration. This multi-functionality is achieved within a single component rather than requiring multiple separate parts
3Strength
If complex assembly processes are used, then structural integrity is achieved, but manufacturing time and cost increase
Solution Approach 1:
The patent performs preliminary actions by pre-forming the complete integral preform structure before resin infusion. The fibre reinforcement material is wound into the final desired geometry with all components integrated, and connection features are built-in during the winding process itself, eliminating the need for subsequent assembly operations
Solution Approach 2:
The patent replaces mechanical assembly operations (bolting, riveting, welding) with a resin infusion process. The resin acts as a chemical binder that bonds all components together during curing, substituting complex mechanical fastening systems with a simpler chemical bonding process that achieves structural integrity without requiring multiple assembly steps
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
This approach reduces manufacturing complexity and cost by creating a lightweight, strong composite stator vane ring that can withstand structural loads, while maintaining aerodynamic functionality, through the use of fibre jointing and resin infusion techniques.
Implementation Method 1
winding fibre reinforcement material around a mandrel to form an inner annulus preform
Implementation Method 2
infusing a thermoset resin into the stator vane ring preform and curing the resin to form the integral stator vane ring
Implementation Method 3
connecting each of the plurality of vane preforms to the inner annulus preform using a fibre jointing method
Data Source
AI summary
Method of manufacturing an integral thermoset infused fibre reinforced composite, structural stator vane ring for a core inlet, a bypass duct, or an air intake of a gas turbine engine. The method comprises winding fibre reinforcement material around a mandrel to form an inner annulus preform; providing a plurality of vane preforms comprising fibre reinforcement material, arranging the plurality of vane preforms around the inner annulus preform, and connecting each of the plurality of vane preforms to the inner annulus preform using a fibre jointing method; winding fibre reinforcement material around the plurality of vane preforms to form an outer annulus preform and connecting the outer annulus preform to each of the plurality of vane preforms using a fibre jointing method to produce a stator vane ring preform; and infusing a thermoset resin into the stator vane ring preform and curing the resin to form the integral stator vane ring.