Polymer-Metal Stator Vanes for Injection-Molded Tolerance Control
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Solution Overview
Problem
Existing gas turbine engine stator vanes, typically made from carbon fiber composites, face high rejection rates due to unmet design tolerances and require improved structural properties to withstand thermal, aerodynamic, and foreign object damage (FOD) loading conditions.
Innovation Solution
Manufacturing stator vanes using a polymer-metal composite structure, where a metallic sheet is embedded in a polymeric substrate, formed through injection molding, to enhance structural integrity and conformity to design tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If carbon fiber composite materials are used for stator vanes, then structural strength and thermal resistance are improved, but manufacturing precision and conformity to design tolerances deteriorate due to human-dependent processes
Solution Approach 1:
The patent uses a composite structure combining polymer substrate and metallic sheet, where the polymer provides manufacturing precision and the metal provides structural strength. This resolves the contradiction by integrating materials with complementary properties rather than relying on a single material system that cannot simultaneously optimize both strength and manufacturing precision.
Solution Approach 2:
The patent replaces human-dependent manual composite layup processes with an automated injection molding process. The injection molding system automatically places and consolidates the metallic sheet within the polymer substrate according to digital toolpaths, eliminating human variability and achieving consistent conformity to design tolerances while maintaining structural strength.
2Reliability
If traditional composite manufacturing processes are used, then structural properties can be achieved, but rejection rates increase due to unmet design tolerances
Solution Approach 1:
The patent replaces manual composite manufacturing with automated injection molding, where robots or automated systems handle material placement, consolidation, and curing. This automation eliminates human error and variability, ensuring consistent adherence to design tolerances and dramatically reducing rejection rates while maintaining required structural properties.
Solution Approach 2:
The patent changes the manufacturing process parameters from manual layup variables to controlled injection molding parameters such as injection pressure, temperature, and cooling rate. These parameters can be precisely controlled and replicated, ensuring consistent product quality and reducing variations that lead to rejections.
3Manufacturing precision
If metallic sheet is embedded in polymeric substrate through injection molding, then manufacturing precision and automation are improved, but process complexity increases
Solution Approach 1:
The patent merges multiple manufacturing steps into a single injection molding cycle: placing the metallic sheet, injecting the polymer material, consolidating the layers, and curing all in one automated process. This integration reduces process complexity despite the advanced capabilities required, as the entire sequence is controlled by a unified automated system rather than separate manual operations.
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-metal composite stator vanes provide improved manufacturing conformity, reduced rejection rates, and enhanced mechanical properties, including FOD resistance, while maintaining comparable thermal and aerodynamic performance.
Implementation Method 1
performing an injection molding process to inject a polymeric material into the mold and thereby form a polymeric substrate that is fixed to the metallic sheet
Implementation Method 2
generating low pressure or vacuum conditions within the one or more vents of the mold to generate a suction force on the metallic sheet and thereby secure the metallic sheet against an interior wall of the mold
Data Source
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AI summary
Stator vanes for gas turbine engines and methods of producing the same are provided. The stator vanes include a body configured to be installed in a bypass of the gas turbine engine such that the body impinges a gas flow within the gas turbine engine during operation thereof. The body has a suction side wall configured to face away from the incoming gas flow and an oppositely disposed pressure side wall configured to face towards the incoming gas flow. The body includes a polymeric substrate formed of a polymer material and a metallic sheet formed of a metallic material. The metallic sheet covers a portion of the polymeric substrate and is at least partially embedded in the polymeric substrate. The polymeric substrate is formed by an injection molding process.