Polymer Fan Annulus Filler with Nanocrystalline Coating

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Solution Overview

Problem

Existing annulus fillers for gas turbine engines are heavy and costly due to their reliance on forged and machined aluminum, which limits their efficiency and scalability.

Innovation Solution

A fan annulus filler made from a polymer with a nanocrystalline coating, where the polymer is injection molded or extruded and coated with a nickel-based alloy, forming reinforcement pins and a shell that eliminates the need for additional machining, providing a lightweight and cost-effective solution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If forged and machined aluminum is used for annulus fillers, then structural strength is improved, but weight increases and manufacturing cost increases

Engineering Contradiction:

Improvestructural strengthVSAvoidweight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent applies composite materials by combining polymer (providing lightweight structure) with nanocrystalline coating (providing structural strength and surface properties). This composite structure achieves the required mechanical strength while significantly reducing weight compared to solid aluminum construction.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent uses a thin polymer shell as the base structure for the annulus filler. This shell provides the basic structural form and is significantly lighter than traditional aluminum construction, while the nanocrystalline coating reinforces it to achieve necessary strength properties.

Inventive Principle:

Principle #30Flexible shells and thin films

2Strength

If forged and machined aluminum is used for annulus fillers, then structural strength is improved, but manufacturing cost increases

Engineering Contradiction:

Improvestructural strengthVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The composite structure of polymer substrate with nanocrystalline coating allows for more efficient manufacturing. The polymer can be formed using injection molding or similar processes, and the nanocrystalline coating is applied through controlled deposition, eliminating the need for expensive forging and machining operations while maintaining structural integrity.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent replaces traditional mechanical manufacturing processes (forging and machining) with material deposition and forming processes. The nanocrystalline coating is deposited onto a pre-formed polymer substrate, substituting the need for mechanical removal of material (machining) and high-energy forming (forging).

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Weight of moving object

If polymer is used for annulus fillers, then weight is reduced and manufacturing cost is reduced, but structural strength decreases

Engineering Contradiction:

ImproveweightVSAvoidstructural strength

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent creates a composite material system where the polymer provides lightweight structure and the nanocrystalline coating provides reinforcement and strength. This combination allows the filler to maintain polymer weight advantages while achieving structural strength comparable to or exceeding traditional aluminum constructions.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the physical and chemical parameters of the polymer structure by applying a nanocrystalline coating. This coating modifies the surface properties and structural characteristics of the polymer, enhancing its mechanical strength, hardness, and other performance parameters without significantly increasing weight.

Inventive Principle:

Principle #35Parameter changes

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 polymer-nanocrystalline coating combination reduces weight and production costs while maintaining structural integrity and performance, offering a scalable alternative to traditional aluminum-based fillers.

Implementation Method 1

a nanocrystalline coating disposed on an exterior surface of the filler body

Methodology Applied

Scientific EffectNanocrystalline coating deposition: Deposition (physical)

Implementation Method 2

forming an annulus filler body with a polymer and coating an exterior surface of the filler body with a nanocrystalline coating

Methodology Applied

Scientific EffectInjection molding:

Implementation Method 3

removing the polymer from the nanocrystalline coating to leave a shell of the nanocrystalline coating

Methodology Applied

Scientific EffectPhase change (polymer removal): Phase Change

Data Source

PatentUS9926798B2Method for manufacturing composite fan annulus filler having nano-coating

Publication Date: 2018.03.27 ROLLS ROYCE CORP

AI summary

A method of making a fan annulus filler for use in a fan assembly of a gas turbine engine may include an annulus filler body formed of a polymer. The annulus filler body may include a surface coated with a nanocrystalline coating to form a flow surface.