Composite Propeller Blade Internal Airflow Channel Design
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Solution Overview
Problem
Current turboprop aircraft propeller blades made of composite materials face interference issues due to their proximity to air intakes, causing distortion and reduced dynamic pressure, which affects engine performance and operability.
Innovation Solution
A method for manufacturing turboprop propeller blades with an internal airflow channel, featuring an input opening at the root and an output opening near the trailing edge, using a 3D RTM composite material process that involves weaving warp and weft yarns to create channels within the blade, allowing airflow to reduce slipstream interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If propeller blades are positioned close to air intake for mass integration, then mass efficiency is improved, but distortion and dynamic pressure drop increase affecting engine performance
Solution Approach 1:
The patent converts the harmful slipstream effect (negative pressure zone) into a beneficial cooling airflow. The internal channel captures the low-pressure slipstream and redirects it through the blade structure to cool the air intake, transforming the harmful pressure drop into useful cooling airflow that maintains mass integration while mitigating performance degradation
Solution Approach 2:
The patent introduces an internal channel as an intermediary structure between the propeller blade and air intake. This channel mediates the interaction by capturing slipstream and redirecting it, allowing the system to maintain close positioning for mass integration while using the intermediary to manage the harmful effects of distortion and pressure drop
2Object-affected harmful factors
If internal airflow channel is added to blade to reduce slipstream, then engine performance is improved, but blade manufacturing complexity increases
Solution Approach 1:
The patent merges the internal airflow channel with the blade's structural framework. The channel is integrated into the blade's internal architecture rather than being a separate component, combining the structural support function with the airflow management function to reduce overall system complexity
Solution Approach 2:
The internal channel serves multiple functions simultaneously: it provides structural support as part of the blade framework, manages airflow to reduce slipstream effects, and enables cooling of the air intake. This multi-functionality reduces the need for separate components, thereby managing complexity
3Object-affected harmful factors
If output opening is positioned at trailing edge for effective slipstream reduction, then aerodynamic performance is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies local quality by positioning the output opening specifically at the trailing edge where the aerodynamic benefits are maximized. This localized precision is concentrated at the critical trailing edge position rather than requiring precision throughout the entire blade, allowing effective slipstream reduction with manageable manufacturing requirements
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
This approach enhances engine performance by minimizing slipstream effects and maintaining mass efficiency, without requiring substantial modifications to existing production machinery.
Implementation Method 1
a densification step of the blade preform by impregnation of said blade preform by material constituting the matrix
Implementation Method 2
an internal airflow channel which comprises an input opening at the root of the blades and an output opening in the vicinity of the trailing edge of the blades such that an internal airflow can circulate from the root to the trailing edge of the blades
Data Source
AI summary
The invention relates to a method for manufacturing a blade made of composite material extending in a main elongation direction, the composite material of said blade comprising a fiber reinforcement densified by a matrix, the method comprising the following steps:a step of weaving warp yarns and weft yarns to produce a fiber preform, the fiber preform comprising at least one warp yarn adapted to form in the matrix at least one first portion of a channel, said portion of length of the warp yarn being directed according to the main elongation direction of the blade and opening at the root of the blade, the first channel portion formed in the matrix by said portion of length of warp yarn constituting at least one first portion of the internal airflow channel;a step of forming the fiber preform so as to produce a blade preform and densifying said blade preform;characterized in that the weaving step comprises placing at least one second portion of yarn adapted to form in the matrix a second portion of a channel, said second portion of yarn being transversally directed relative to said main elongation direction and opening at the trailing edge of the blade, the second channel portion formed in the matrix by said second portion of yarn constituting also at least one second portion of the internal airflow channel.