Thin-edged Composite Blade Fibrous Texture Design
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Solution Overview
Problem
Current three-dimensional or multilayer weaving techniques for composite material blades cannot effectively form very thin leading and trailing edges while maintaining sufficient mechanical strength, as they require at least three weft layers bound by three warp layers, which limits the ability to produce blades with thin edges that meet new aerodynamic requirements.
Innovation Solution
A fibrous texture with a single-piece three-dimensional or multilayer weave structure, featuring a blade aerofoil part with varying yarn layers and binding frequencies at the edges, allowing for a minimum thickness while maintaining mechanical strength, by using two yarn layers at the edges with adjusted binding frequencies and densities to optimize weaving and deformation capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If at least three weft layers bound by three warp layers are used in 3D or multilayer weaving, then mechanical strength is ensured, but the ability to form very thin leading and trailing edges is limited
Solution Approach 1:
The patent applies different weaving structures to different regions of the blade. The blade root uses a conventional three-layer warp and weft structure for high mechanical strength, while the blade edges use a two-layer warp and weft structure to achieve very thin thickness. This local differentiation allows each region to have optimal properties for its specific function.
Solution Approach 2:
The fibrous texture is divided into distinct zones: a first part with at least three warp layers and three weft layers for the blade root, and a second part with only two warp layers and two weft layers for the blade edges. This segmentation enables the transition from thick, strong structures at the root to thin, aerodynamic edges at the tip.
2Length of moving object
If two yarn layers are used at the edges to reduce thickness, then edge thinness is achieved, but mechanical strength may be compromised
Solution Approach 1:
The patent changes the binding frequency parameter in the two-layer edge regions. By increasing the binding frequency (number of binding points per unit length), the structural integrity is enhanced despite using fewer layers. This parameter adjustment compensates for the reduced number of warp and weft layers, maintaining sufficient mechanical strength in the thin edge regions.
Data Source
AI summary
A fibrous texture for a blade has a three-dimensional weave between a first plurality of yarn layers and a second plurality of yarn layers, includes a blade aerofoil part extending between a first edge and a second edge. The texture includes a first part with at least three yarn layers of the first plurality of yarns and at least three yarn layers of the second plurality of yarns. Yarns of the two yarn layers of the first plurality of yarns bind yarns of the second plurality of yarns to the two yarn layers of the second plurality of yarns with a determined binding frequency.