Morphable Composite Structure with Conductive Particles
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Solution Overview
Problem
Existing composite structures for turbine engine blades lack the ability to dynamically change shape in response to operational conditions, limiting their efficiency and adaptability during transient operations.
Innovation Solution
A morphable composite structure comprising layers with parallel structural fibers and electrically-conductive particles, where a current is directed through the particles to heat and alter the shape of the fibers, allowing the structure to change shape and adjust its operating properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If composite blade is formed from multiple layers with asymmetrical fiber orientation, then the blade can change shape during operation, but the blade cannot dynamically control or optimize its shape for different operating conditions
Solution Approach 1:
The patent applies the dynamics principle by transforming the static composite blade structure into a dynamic one capable of shape change. This is achieved by incorporating shape memory alloy (SMA) wires within the composite layers that can actively change their mechanical properties in response to temperature changes, enabling the blade to dynamically adjust its shape during operation rather than being fixed or passively changing.
Solution Approach 2:
The patent applies parameter changes by utilizing the temperature-dependent properties of shape memory alloys. The SMA wires undergo phase transitions (martensite-austenite) when exposed to different temperatures, causing significant changes in their stiffness and length. This allows the blade shape to be controlled by changing the thermal parameter, enabling adaptation to different operating conditions without mechanical moving parts.
2Productivity
If traditional composite blade structure is used, then manufacturing is simpler, but the blade cannot optimize efficiency during transient operations
Solution Approach 1:
The patent applies composite materials by combining traditional composite materials (fibers and matrix) with shape memory alloy wires to create a multi-material composite structure. This hybrid composite enables the blade to maintain the benefits of traditional composites (strength, stiffness) while adding the capability for active shape control through the SMA elements, thereby improving operational efficiency during transient operations.
Solution Approach 2:
The patent applies mechanics substitution by replacing traditional mechanical actuation systems (such as hydraulic actuators or mechanical linkages) with a thermal-field-based control system using shape memory alloys. The SMA wires respond to thermal input by undergoing phase transitions that directly produce mechanical shape changes, eliminating the need for complex mechanical actuation mechanisms while achieving blade shape optimization.
3Adaptability or versatility
If asymmetrical fiber orientation is used to enable shape change, then the blade can adapt shape, but control precision and reliability are reduced
Solution Approach 1:
The patent applies local quality by strategically placing shape memory alloy wires at specific locations within the composite blade structure where shape control is needed. The SMA wires are embedded in particular layers and orientations to provide localized shape adjustment capabilities, allowing precise control of specific blade regions while maintaining the overall structural integrity and reliability of the blade.
Solution Approach 2:
The patent applies feedback by implementing a control system that monitors blade operating conditions (such as temperature, pressure, or flow conditions) and adjusts the thermal input to the SMA wires accordingly. This closed-loop control ensures that the blade shape is reliably adjusted to optimal configurations for different operating conditions, enhancing shape control reliability through active feedback regulation.
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
Enables the turbine engine to optimize its shape and efficiency by changing the shape of compressor vanes, enhancing operating characteristics and reducing losses during transient conditions.
Implementation Method 1
A current can be directed through the pattern to heat the plurality of fibers of the first layer and change the shape of the morphable composite structure
Data Source
AI summary
A morphable composite structure includes at least first and second layers fixed relative to one another. Each of the first and second layers includes structural fibers oriented substantially parallel to one another and a quantity of binder substantially fixing the structural fibers together. The fibers of the first layer are oriented asymmetrically to the fibers of the second layer. The morphable composite structure also includes at least one pattern of electrically-conductive particles connected with the first layer and spaced from the second layer. A current can be directed through the pattern to heat the fibers of the first layer and change the shape of the morphable composite structure.