Nanoparticle-Reinforced Composite Fan Case for Blade Impact Containment
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Solution Overview
Problem
Fiber reinforced polymer composite materials used in fan casings for gas turbine engines face challenges in absorbing impact energy without compromising structural integrity due to fiber breakage and pull-out, which reduces load-carrying capability and structural integrity post-impact.
Innovation Solution
A composite fan case design incorporating an inner structure assembly with a resin-impregnated honeycomb structure and an outer structure assembly with resin-reinforced nanoparticles, allowing blade fragments to puncture and impact while minimizing delamination and energy absorption through polymer resin and nanoparticles, maintaining structural integrity and reducing fiber breakage and pull-out.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If fiber reinforced polymer composite material is used in fan casing to reduce weight, then weight is reduced, but fiber breakage and pull-out occur during impact which reduces structural integrity
Solution Approach 1:
The patent uses fiber reinforced polymer composite material for the fan casing to achieve weight reduction while maintaining strength. The composite structure with fibers embedded in polymer matrix provides high strength-to-weight ratio, allowing the fan case to be lighter than metal alternatives while retaining adequate structural integrity for blade containment.
Solution Approach 2:
The patent modifies the impact resistance parameters by designing specific structural features including energy absorption zones, reinforcement rings, and controlled delamination paths. These parameter changes allow the composite material to better withstand impact forces by controlling how energy is distributed and absorbed during blade failure events.
2Loss of energy
If fiber breakage and pull-out are used to absorb impact energy, then impact energy is absorbed, but load carrying capability and structural integrity are reduced
Solution Approach 1:
The patent divides the fan case structure into distinct functional zones: an inner structure assembly with honeycomb core for energy absorption, and an outer structure assembly with fiber reinforcement for maintaining structural integrity. This segmentation allows different regions to perform different functions - the inner structure absorbs impact energy through controlled deformation while the outer structure maintains load carrying capability.
Solution Approach 2:
The patent applies different material properties and structural characteristics to different regions of the fan case. The inner structure uses honeycomb core with specific cell structures optimized for energy absorption, while the outer structure uses fiber reinforced layers with orientations designed to maintain strength. This local differentiation allows optimal performance for both energy absorption and structural integrity.
3Strength
If thicker composite layers are used to maintain structural integrity, then strength is improved, but weight increases
Solution Approach 1:
The patent employs composite materials with high strength-to-weight ratio characteristics, using fiber reinforced polymers that provide superior specific strength compared to conventional materials. This allows achieving required structural integrity with thinner, lighter sections rather than requiring thick metal walls.
Solution Approach 2:
The patent utilizes thin-walled composite structures with optimized layer configurations that provide adequate strength through material properties rather than thickness. The fiber reinforced polymer layers are designed as thin films that maintain structural integrity through their inherent material strength and structural design features like reinforcement rings and stiffeners.
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
The design enhances structural strength and stiffness, enabling safe engine shutdown and landing after blade impact by reducing fiber breakage and pull-out, while also reducing weight and peak impact loads on the fan case.
Implementation Method 1
absorbing energy released from the impact between the outer structure assembly and the blade fragments using a polymer resin impregnated within the outer structure assembly
Implementation Method 2
the resin impregnating the one or more layers of the inner and outer structure assemblies comprises nanoparticles therein
Data Source
AI summary
A composite case for a gas turbine engine includes an inner structure assembly defining an impact containment zone. The inner structure assembly is configured to circumscribe a plurality of rotatable blades of the gas turbine engine and to receive blade fragments in an event of blade failure. The inner structure assembly includes one or more layers containing a resin impregnated therein, and an outer structure assembly surrounding the inner structure assembly and integrally molded thereon. The outer structure assembly includes one or more layers containing a resin impregnated therein. One or more layers of the inner and the outer structure assemblies include resin reinforced by nanoparticles.