Gas Turbine Spinner Using Chopped Unidirectional Fiber Composite
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Solution Overview
Problem
The existing materials used for spinners in gas turbine engines, such as metals and two-dimensional para-aramid laminates, are expensive and heavy, leading to increased fuel consumption and operational costs due to their high material costs and weight, which do not meet the FAR requirements effectively.
Innovation Solution
A spinner body made of a nonwoven mat of chopped unidirectional fiber pre-impregnated material with a conical shape, utilizing fibers like carbon, graphite, or ceramic, combined with thermoset or thermoplastic resins, and optionally plated with metals like aluminum or titanium alloys, is used to reduce material costs and weight while maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metals or two-dimensional para-aramid laminates are used to manufacture spinners, then structural integrity and strength are improved, but weight and material cost increase
Solution Approach 1:
The patent applies composite materials by combining chopped unidirectional fiber pre-impregnated material with resin to create a spinner body that achieves the required structural integrity while significantly reducing weight compared to traditional metal or para-aramid laminate constructions. The composite structure leverages the high strength-to-weight ratio of fiber-reinforced materials.
Solution Approach 2:
The patent changes the material parameters by transitioning from continuous fiber laminates to chopped unidirectional fiber pre-impregnated material, altering the physical and mechanical properties to achieve an optimal balance between strength, weight, and manufacturability for the spinner application.
2Strength
If metals or two-dimensional para-aramid laminates are used to manufacture spinners, then structural integrity is improved, but material cost increases
Solution Approach 1:
The patent uses composite materials made from chopped unidirectional fiber pre-impregnated material combined with resin, which provides the necessary structural integrity at a lower material cost compared to traditional metals or para-aramid laminates, thereby improving the ease of manufacture.
Solution Approach 2:
The patent adopts a cost-effective material approach by using chopped unidirectional fiber pre-impregnated material, which is more economical than expensive metal or para-aramid laminate alternatives, reducing overall manufacturing costs while maintaining required performance.
3Strength
If heavier materials are used for spinners, then structural integrity is improved, but fuel consumption increases
Solution Approach 1:
The patent applies composite materials to reduce spinner weight while maintaining structural integrity, directly decreasing the overall engine weight and thereby reducing fuel consumption during aircraft operations.
Solution Approach 2:
The patent effectively counteracts the weight penalty by using lightweight composite materials, offsetting the gravitational effect of the spinner's mass and reducing the energy required for flight operations.
Data Source
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AI summary
A spinner (60;76) for a gas turbine engine (20) is disclosed. The spinner (60;76) may include a body (66) extending between a first and second end (62,64) comprised of a cured chopped unidirectional fiber pre-impregnated material. The body (66) may have a generally conical shape and may further be plated with a metal or metal alloy.