Integral Tip Turbine Engine Case with Inlet Guide Vanes
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Solution Overview
Problem
Conventional turbofan engines require separate and complex engine cases for the bypass fan, low pressure compressor, combustor, and turbine, leading to laborious and expensive assembly processes due to their axial flow relationship.
Innovation Solution
The development of a tip turbine engine with an integral engine case that includes a radially outward fan and combustor, featuring an integral case portion with an inlet guide vane formed through a casting process, and a composite layer with woven Kevlar fiber reinforcement, allowing for a unitary engine case that integrates the fan, combustor, and turbine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate engine cases are used for bypass fan, low pressure compressor, combustor, and turbine in conventional turbofan engines, then each component can be independently manufactured and maintained, but the assembly process becomes laborious and expensive with multiple joints and structural attachments
Solution Approach 1:
The patent merges multiple separate engine cases (bypass fan case, low pressure compressor case, combustor case, and turbine case) into a single integrated engine case structure. This consolidation eliminates the need for multiple joints and structural attachments between separate cases, directly reducing assembly labor and structural complexity while maintaining the functional separation of engine components through internal positioning and support structures.
2Productivity
If an integrated one-piece engine case is provided for tip turbine engine, then assembly labor and costs are reduced, but manufacturing complexity and casting requirements increase
Solution Approach 1:
The integrated engine case is manufactured as a unitary structure through a single casting process, eliminating the need to assemble multiple separate cases. This segmentation principle is applied in reverse - instead of dividing the engine case into multiple manufacturable sections that require assembly, the entire case is cast as one piece, thereby eliminating assembly labor and joints while managing manufacturing complexity through advanced casting techniques.
3Device complexity
If inlet guide vanes are integrally formed with the engine case through casting, then the number of parts and assembly steps are reduced, but precision control of vane geometry and positioning becomes more difficult
Solution Approach 1:
The inlet guide vanes are pre-formed as integral portions of the engine case during the casting process itself, rather than being manufactured separately and attached later. This preliminary action of forming the vanes directly in the casting mold ensures precise geometric control and positioning is built into the manufacturing process from the beginning, eliminating subsequent assembly steps while maintaining or improving geometric precision through dedicated mold design and casting process control.
Data Source
AI summary
A tip turbine engine assembly includes an integral engine outer case located radially outward from a fan assembly. The integral outer case includes a rear portion and a forward portion with an arcuate portion that curves radially inwardly to form a compartment. An annular combustor is housed and mounted in the compartment. Fan inlet guide vanes are integrally formed with the arcuate portion to form the integral case portion. The rear portion, forward portion, and fan inlet guide vanes are integrally formed in a casting process.