Tapered Composite Backsheet for Turbine Engine Containment
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Solution Overview
Problem
Existing rotor section containment assemblies in gas turbine engines are overdesigned due to constant thickness backsheet structures, leading to increased weight and manufacturing costs, as they do not account for varying strength requirements along the length of the backsheet.
Innovation Solution
A backsheet with tapered portions and a constant thickness section, fabricated from composite materials, is designed to provide tailored thickness based on load concentrations, reducing weight and costs while ensuring strength and stiffness during blade-out conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a constant thickness backsheet is used to satisfy strength requirements, then strength is improved, but weight increases
Solution Approach 1:
The backsheet is designed with varying thickness along its length, with thicker sections at locations requiring higher strength (such as near support structures) and thinner sections where lower strength is acceptable. This local differentiation of thickness provides the necessary strength at each location while minimizing overall weight compared to a uniform thickness design.
Solution Approach 2:
The thickness parameter of the backsheet is changed along its length to optimize the strength-to-weight ratio. By adjusting the thickness parameter locally rather than maintaining a constant value, the design achieves adequate strength where needed while reducing material usage and weight in less critical areas.
2Strength
If a constant thickness backsheet is used to ensure uniform strength, then strength is improved, but manufacturing costs increase
Solution Approach 1:
The backsheet features localized thickness variations that match the actual strength requirements at different positions. This allows manufacturing resources to be concentrated where needed rather than uniformly across the entire backsheet, reducing overall material consumption and manufacturing costs while maintaining necessary strength.
Solution Approach 2:
Instead of providing full thickness throughout the entire backsheet, the design applies full thickness only where absolutely necessary for strength, and reduces thickness in areas where lower strength is acceptable. This partial application of maximum thickness optimizes the balance between strength requirements and manufacturing cost.
3Weight of moving object
If a tapered backsheet design is used to reduce weight, then weight is improved, but structural complexity increases
Solution Approach 1:
The backsheet is divided into multiple zones or segments with different thickness characteristics. This segmentation allows each zone to be optimized for its specific structural requirements while maintaining overall simplicity. The segmented approach makes the complex thickness variation more manageable in terms of design and manufacturing.
Solution Approach 2:
The thickness parameter is systematically varied along the backsheet length following a controlled pattern (such as linear or quadratic tapering). This systematic parameter change creates a predictable gradient that reduces weight while maintaining manufacturability, avoiding arbitrary or overly complex thickness variations.
Data Source
AI summary
A backsheet for use in a turbine engine fan case includes a first portion including a first portion first end and an opposing first portion second end. The first portion is tapered between the first portion first end and the first portion second end. The backsheet also includes a second portion coupled to the first portion. The second portion includes a second portion first end and an opposing second portion second end. The second portion defines a constant thickness between the second portion first end and the second portion second end.