Turbine Engine Composite Structure With Turned-In Woven Struts
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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, where bifurcated strut portions are turned inside-out to form a woven outer shell hoop preform, connected to an inner hub, and infused with a matrix material, followed by curing to create a composite component with enhanced structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional two-dimensional layup designs are used for composite gas turbine engine components, then manufacturing processes are simple and familiar, 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 three-dimensional woven fabric preforms. This dimensional change enables fibers to extend in multiple directions (through-thickness, radial, and circumferential directions) rather than being confined to planar layers, thereby improving interlaminar strength and structural integrity while maintaining manufacturability through automated resin infusion processes
2Ease of manufacture
If traditional two-dimensional layup designs are used, then manufacturing processes are straightforward, but labor-intensive hand layup and preform assembly are required, increasing manufacturing costs
Solution Approach 1:
The patent employs pre-formed three-dimensional woven fabric preforms that are prepared beforehand with specific fiber architectures (including through-thickness, radial, and circumferential fiber orientations). These preforms are then assembled into the final component shape and subjected to resin infusion and curing, eliminating the need for labor-intensive hand layup during production and significantly improving manufacturing efficiency
Solution Approach 2:
The patent replaces manual hand layup operations with automated resin infusion processes. The preformed three-dimensional woven fabrics are placed in molds and resin is infused under controlled pressure and temperature conditions, substituting labor-intensive mechanical assembly with automated chemical-physical processes that improve productivity and consistency
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 method improves manufacturing efficiency and interlaminar strength, reducing labor costs and enhancing the structural integrity of composite components for turbine engines.
Implementation Method 1
infused with a matrix material
Implementation Method 2
followed by curing to create a composite component
Data Source
Figure 1
Figure 2A~2B
Figure 2C~2D
AI summary
A method of manufacturing a composite component (161) having an outer shell (165), an inner hub (167), and a plurality of struts (158) connecting the outer shell (165) and the inner hub (167). An initial outer shell hoop preform (302a) includes a plurality of bifurcated strut portions (306, 334, 336, 346, 348, 350, 352, 364, 366, 376, 378, 380, 382) on an exterior side (504) of the initial outer shell hoop preform (302a). The initial outer shell hoop preform (302a) is turned inside-out to form a woven outer shell hoop preform (302b) so that the bifurcated strut portions (306, 334, 336, 346, 348, 350, 352, 364, 366, 376, 378, 380, 382) are arranged on the interior side (504') of the woven outer shell hoop preform (302b) to extend inward. The woven outer shell hoop preform (302b) is installed on a mold tooling structure (508), along with an inner hub preform (304), and the bifurcated strut portions (306, 334, 336, 346, 348, 350, 352, 364, 366, 376, 378, 380, 382) are connected to inner hub pi-joint members (309, 390, 392, 394, 396, 398, 400, 402, 404, 406, 408, 410, 412, 414) of the inner hub preform (304). A matrix material is injected into the mold tooling structure (508) and a curing process is applied to the mold tooling structure (508) to obtain the composite component (161).