Integrated Turbofan Ducting and Front Frame
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Solution Overview
Problem
The existing turbofan engine front frame and outer flowpath ducting systems are heavy and costly, with multiple assembly interfaces that hinder weight reduction and efficient load distribution, impacting the thrust-to-weight ratio and overall engine competitiveness.
Innovation Solution
An integrated outer flowpath ducting and front frame system featuring a primary composite load path with aerodynamically configured fairings and load-bearing metal struts, decoupling aerodynamic and weight-bearing duties to minimize assembly interfaces and optimize weight distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional separate front frame and outer flowpath ducting systems are used, then structural strength and load-bearing capacity are maintained, but overall engine weight increases and manufacturing complexity increases
Solution Approach 1:
The patent combines the front frame and outer flowpath ducting into a single integrated structure. The front frame assembly includes a hub, fairings, and load-bearing struts that are coupled to the outer flowpath ducting, eliminating the need for separate structural components. This merging reduces the number of parts and assembly interfaces while maintaining the required load-bearing capacity through the load-bearing struts that transfer mechanical loads between the engine core and the outer flowpath ducting.
2Ease of manufacture
If multiple assembly interfaces are used to connect engine components, then structural integrity and load distribution are ensured, but manufacturing complexity and assembly time increase
Solution Approach 1:
The integrated design merges the front frame and outer flowpath ducting into one structure, reducing the number of assembly interfaces. Instead of multiple separate components requiring multiple connections, the load-bearing struts provide direct load transfer paths from the hub through the fairings to the outer flowpath ducting, simplifying the assembly process while maintaining structural integrity.
3Productivity
If aerodynamic fairings and load-bearing struts are integrated, then aerodynamic performance and structural function are optimized, but manufacturing complexity increases
Solution Approach 1:
The patent segments the integrated structure into functional modules: the hub, aerodynamic fairings, load-bearing struts, and outer flowpath ducting. Each component is designed to perform its specific function while being part of the integrated assembly. The fairings are aerodynamically configured to guide airflow, while the load-bearing struts provide structural support and load transfer, allowing for optimized manufacturing of each segment while maintaining overall integration.
4Weight of moving object
If lightweight materials and reduced part count are used, then overall engine weight is reduced, but structural strength and load distribution may be compromised
Solution Approach 1:
The patent employs composite materials in the outer flowpath ducting and fairings to achieve weight reduction while maintaining structural strength. The composite construction allows for high strength-to-weight ratio, enabling the integrated structure to bear mechanical loads effectively while being lighter than traditional metallic constructions. The load-bearing struts are designed to work in conjunction with the composite structures to distribute mechanical loads efficiently.
Data Source
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AI summary
A system and method is provided for an integrated aircraft turbofan engine outer flowpath ducting and front frame that minimizes assembly interfaces and reduces overall aircraft engine weight. The system and method provide an integrated turbofan engine outer flowpath ducting and front frame system that decouples the fairing/aerodynamic duties from the struts/weight bearing duties thereby enabling efficient distribution of mechanical load.