Rotor Fan Composite Hub and Blade Structure for High-Stress Loading
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Solution Overview
Problem
Rotor components made of composite materials face challenges with lower loading and stress tolerances, posing issues for high structural integrity under high mechanical stress, temperature fluctuations, and impact loads, while also being difficult to recycle and produce in high volumes.
Innovation Solution
The rotor fan is designed with rotor blades and a hub made of fiber-reinforced composite materials, using continuous fibers embedded in a matrix, with specific orientations and weaving patterns, and a combination of molding processes to ensure structural integrity and efficient production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If rotor components are made of composite materials to reduce weight and cost, then weight and manufacturing cost decrease, but loading and stress tolerances deteriorate
Solution Approach 1:
The patent uses fiber-reinforced composite materials with continuous fibers arranged in specific orientations (0°, ±45°, 90°) to achieve both weight reduction and high strength. The composite structure combines lightweight properties with enhanced mechanical properties through strategic fiber placement and material selection.
Solution Approach 2:
The patent applies different fiber orientations and material compositions to specific regions of the rotor blade to optimize local mechanical properties. The blade features varying fiber angles and stacking sequences in different sections to handle specific stress patterns while maintaining overall weight efficiency.
2Reliability
If complex fiber arrangements and metal reinforcements are used to improve structural integrity, then strength and reliability improve, but manufacturing complexity and production time increase
Solution Approach 1:
The patent integrates multiple functions into the composite structure itself, eliminating the need for separate metal reinforcement elements. The fiber-reinforced composite blade incorporates all structural requirements directly in the molding process, combining strength, aerodynamics, and manufacturing efficiency in a single integrated component.
Solution Approach 2:
The patent optimizes manufacturing parameters including fiber orientation angles, stacking sequences, and curing conditions to achieve high structural integrity through the molding process itself, rather than requiring post-manufacturing assembly or reinforcement additions.
3Ease of manufacture
If traditional molding processes are used for composite rotor blades, then manufacturing simplicity is maintained, but production volume and efficiency are limited
Solution Approach 1:
The patent uses pre impregnated fiber preforms where fibers are pre-coated with resin before molding. This preliminary preparation allows for faster molding cycles and higher production volumes while maintaining manufacturing simplicity, as the pre-prepared preforms can be quickly placed and cured in the mold.
Solution Approach 2:
The patent replaces traditional mechanical assembly processes with advanced molding techniques that form the complete rotor blade in a single casting operation. This substitution enables high-volume production while maintaining the simplicity of the manufacturing process through automated molding and curing.
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 achieves high mechanical stability, efficient mass production, and recyclability, while maintaining aerodynamic efficiency and reducing material and manufacturing costs.
Implementation Method 1
a fiber reinforced composite material, which comprises reinforcing fibers that are embedded in a surrounding matrix material
Implementation Method 2
The rotor blades each typically comprise a blade body, which extends in a longitudinal direction between a bottom portion and a top portion
Data Source
AI summary
The present disclosure relates to a rotor fan (1) for an airborne vehicle, which comprises several rotor blades (2) arranged rotationally symmetric around a rotor axis (3). Each rotor blade (2) comprises a blade body (4) which is made of a composite material comprising reinforcing fibers (5) embedded in a matrix material (6) and extends in a longitudinal direction (7) between a bottom portion (8) and a top portion (9) and in transverse direction (10) between a leading edge (11) and a trailing edge (12). The rotor fan (1) further comprises a hub (13) with a hub body (13) which is at least partially made of a composite material comprising reinforcing fibers (14) embedded in a matrix material (15). The bottom portion (8) of each rotor blade (2) comprises a pedestal (17) which is at least partially embedded in the composite material of the hub (13).