Integrated Aero-Engine Flowpath Structure with Aligned Fiber Plies
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Solution Overview
Problem
Existing aero-engine structures face challenges in withstanding both aerodynamic and structural loads without the need for metal or metallic backing structures, particularly due to limitations in materials like carbon-carbon which have low inter-laminar shear strength and thermal expansion mismatches.
Innovation Solution
An integrated aero-engine flowpath structure using composite materials such as carbon-carbon, with aligned fiber plies in structural joints to reduce inter-laminar shear stresses, and a ramburner/nozzle design that employs co-bonded composite linking structures to transfer mechanical loads without additional backing, utilizing carbon-carbon and other ceramic matrix composites.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If carbon-carbon composite materials are used to withstand thermal and mechanical loads, then the aero-engine can operate at high temperatures without metal backing structures, but the low inter-laminar shear strength causes structural integrity issues at bond joints
Solution Approach 1:
The patent employs carbon-carbon composite materials with specifically aligned fiber orientations in different plies. The fiber alignment is designed so that fibers run continuously through bond joints, creating a unified structural path that eliminates weak inter-laminar interfaces. This composite structure allows the material to withstand both thermal loads and mechanical shear stresses without requiring metal backing structures.
2Ease of manufacture
If traditional composite structures are used without aligned fiber plies, then manufacturing is simpler, but thermal expansion mismatches cause structural failure at bond joints
Solution Approach 1:
The patent implements different fiber alignment configurations in different regions of the composite structure. In bond joint areas, fibers are aligned to match the thermal expansion characteristics of adjacent components, while in other regions, fibers may be oriented for optimal mechanical strength. This localized optimization of fiber orientation addresses thermal expansion mismatches at critical interfaces without requiring complex manufacturing procedures throughout the entire structure.
3Strength
If additional metal backing structures are added to support carbon-carbon composites, then structural integrity improves, but weight increases and aerodynamic efficiency decreases
Solution Approach 1:
The patent removes the unnecessary metal backing structures from the design by creating a self-supporting carbon-carbon composite structure. The composite material itself is engineered with aligned fiber plies that provide the required structural integrity, eliminating the need for additional metal support elements. This extraction of redundant components reduces weight and improves aerodynamic efficiency while maintaining structural strength.
4Strength
If aligned fiber plies are implemented in structural joints, then inter-laminar shear stresses are reduced, but manufacturing complexity increases
Solution Approach 1:
The patent incorporates fiber alignment considerations into the preliminary design and tooling preparation stages. By pre-configuring the fiber reinforcement patterns and alignment fixtures before manufacturing, the complex alignment requirements are built into the manufacturing process itself rather than requiring complex post-processing or adjustment. This preliminary action approach maintains bond joint strength while making the manufacturing process more manageable.
Data Source
AI summary
One embodiment of the present invention is an integrated aero-engine flowpath structure. Another embodiment is a method of manufacturing integrated aero-engine flowpath structure. Other embodiments include apparatuses, systems, devices, hardware, methods, and combinations for aero-engine flowpath structures. Further embodiments, forms, features, aspects, benefits, and advantages of the present application shall become apparent from the description and figures provided herewith.