Turbine Engine Composite Structure with 3D-Woven Strut Preforms
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Solution Overview
Problem
Traditional two-dimensional layup designs for composite gas turbine engine components are challenging to manufacture, requiring labor-intensive hand layup and preform assembly, leading to increased costs and limited interlaminar strength.
Innovation Solution
A method of manufacturing composite components using a three-dimensional woven fabric preform assembly, which includes an outer shell, inner hub, and struts, with a matrix material injection and curing process to form a composite component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional two-dimensional layup designs are used for composite gas turbine engine components, then manufacturing can be performed with conventional processes, but labor-intensive hand layup and preform assembly are required leading to increased costs and limited interlaminar strength
Solution Approach 1:
The patent transitions from traditional two-dimensional layup designs to a three-dimensional preform assembly approach. The preform includes an outer shell, inner hub, and struts arranged in three dimensions, allowing matrix material to be injected and cured to form a composite component with enhanced interlaminar strength while simplifying the manufacturing process.
Solution Approach 2:
The patent uses composite materials by combining a matrix material (such as polymer, metal, or ceramic) with a three-dimensional preform structure. This composite approach allows the preform to provide structural framework while the matrix material binds the components together, creating a stronger composite component with improved interlaminar properties.
2Productivity
If traditional hand layup and preform assembly methods are used, then manufacturing flexibility is maintained, but labor intensity increases and manufacturing costs rise
Solution Approach 1:
The preform assembly is prepared in advance with the outer shell, inner hub, and struts already positioned and configured. This preliminary arrangement of components before matrix material injection eliminates the need for labor-intensive hand layup during manufacturing, significantly reducing labor time and increasing productivity.
Solution Approach 2:
The patent combines multiple components (outer shell, inner hub, struts) into a single integrated preform assembly that is manufactured as one piece. This merging of components into a unified preform structure simplifies the manufacturing process and eliminates the need for separate assembly operations, thereby reducing labor requirements and manufacturing time.
3Reliability
If three-dimensional woven fabric preform assembly is used, then interlaminar strength and structural integrity are improved, but the manufacturing process becomes more complex
Solution Approach 1:
The three-dimensional preform assembly is segmented into distinct functional components: an outer shell for structural containment, an inner hub for central support, and struts for radial reinforcement. This segmentation allows each component to be optimized for its specific function while maintaining overall structural integrity, and the modular nature simplifies the manufacturing process compared to monolithic designs.
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
Enhances manufacturing efficiency and interlaminar strength, reducing labor and costs while improving the structural integrity of composite components.
Implementation Method 1
injecting a matrix material into the mold tooling structure, and applying a curing process to the mold tooling structure to obtain a molded composite component
Data Source
Figure 1
Figure 2A~2B
Figure 2C~2D
AI summary
A method of manufacturing a composite component (161') including an outer shell (165), an inner hub (167), and a plurality of struts (158) connecting the outer shell (165) and the inner hub (167). The method includes installing (S1802) an outer shell hoop preform (302) on a mold tooling structure (440), installing (S1802) an inner hub hoop preform (304) on the mold tooling structure (440), and inserting (S1804) strut preforms (306) through outer shell strut slots (308, 310, 312, 314, 316, 318, 320,322, 324), and through inner hub strut slots (338, 340, 342, 344, 346, 348, 350, 352, 354). A first end (366) of the strut preform (306) has bifurcated end portions (370, 372) that are overlayed onto the outer shell hoop preform (302), and a second end (368) of the strut preform (306) has bifurcated end portions (374, 376) that are overlayed onto one of the outer shell hoop preform (302) or the inner hub hoop preform (304). A matrix material is injected (S1809) into the mold tooling structure (440) and a curing process is applied (S1810) to the mold tooling structure (440) to obtain a molded composite component (161').