Integrated Fan Case Stator Vanes Composite Design
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Solution Overview
Problem
Conventional gas turbine engine fan cases and stator vanes are often made from separate components, leading to increased weight, complexity, and potential failure points, particularly in high-stress conditions like blade out scenarios, where containment and structural integrity are compromised.
Innovation Solution
The integration of fan cases and stator vanes using a resin transfer molding process with a polymer matrix composite material, comprising reinforcing fibers such as carbon, aramid, glass, or ceramic fibers bound by polyimide or bismaleimide resin, forming a unitary structure that enhances containment and structural performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If fan case and stator vanes are made as separate components, then manufacturing flexibility is improved, but weight and structural integrity deteriorate
Solution Approach 1:
The patent merges the fan case and stator vanes into a single integrated component formed by resin transfer molding. This consolidation eliminates the need for separate manufacturing and assembly operations, reducing overall weight while maintaining manufacturing feasibility through a single mold cavity process.
Solution Approach 2:
The patent employs composite materials consisting of reinforcement fibers (carbon, aramid, glass, or ceramic) bound by a polymer matrix (polyimide or bismaleimide). This composite construction achieves high strength-to-weight ratio, providing both structural integrity and weight reduction compared to traditional metal constructions.
2Ease of manufacture
If fan case and stator vanes are made as separate components, then manufacturing simplicity is improved, but containment capability and structural integrity deteriorate
Solution Approach 1:
By combining the fan case and stator vanes into a single integrated component, the patent eliminates potential failure points at interfaces between separate parts. The unified structure provides enhanced containment capability while the resin transfer molding process ensures homogeneous material distribution and strong internal bonding.
Solution Approach 2:
The use of fiber-reinforced polymer matrix composites provides superior strength properties and containment capability. The reinforcement fibers distributed within the polymer matrix create a homogeneous structure that resists failure under high-stress conditions, including blade out scenarios.
3Ease of manufacture
If conventional materials are used for fan case, then manufacturing cost is reduced, but temperature resistance and structural integrity deteriorate
Solution Approach 1:
The patent utilizes high-temperature resistant polymer matrix materials (polyimide or bismaleimide) combined with reinforcement fibers to construct the fan case. These composite materials maintain structural integrity at elevated temperatures where conventional metals would be too heavy and costly, achieving both thermal resistance and cost-effectiveness.
4Adaptability or versatility
If multiple separate components are used, then design flexibility is improved, but device complexity and potential failure points increase
Solution Approach 1:
The patent integrates multiple functions (fan case containment, stator vane airflow guidance) into a single component. This reduction in part count simplifies the overall device while design flexibility is maintained through the moldability of composite materials, allowing complex geometries to be formed in one piece.
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 integrated design reduces weight and component count, while providing enhanced containment capabilities, high temperature resistance, and improved structural integrity, particularly in scenarios like blade out conditions, by leveraging the strength and durability of polymer matrix composites.
Implementation Method 1
The fan case and stator vanes are formed using a resin transfer molding process
Implementation Method 2
the polymer matrix composite material comprises reinforcing fibers bound together by a polymer matrix
Data Source
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AI summary
A gas turbine engine (10) according to an exemplary aspect of the present invention comprising, a fan case (62) and a plurality of stator vanes (64) integrally formed with the fan case (62). A method is also disclosed.