Composite Turbomachine Vane Core With Closed Cavities
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Solution Overview
Problem
The fragility of foams used in composite material blades for turbomachines makes it difficult to manufacture blades without damaging the core, limiting the potential for reducing blade mass and increasing resistance to manufacturing forces.
Innovation Solution
A stator blade with a core made of non-porous plastic material, featuring a closed cavity that allows for a lighter core while providing the necessary strength and resistance during manufacturing, and an aerodynamic profile shape that aids in shaping the shell during consolidation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a foam core is used to reduce blade mass, then the blade becomes lighter, but the core becomes too fragile to withstand manufacturing operations
Solution Approach 1:
The patent changes the material parameters of the core from foam to non-porous plastic material. This material substitution maintains the lightweight benefit while fundamentally altering the mechanical properties to provide sufficient strength and resistance during manufacturing operations, directly resolving the contradiction between mass reduction and structural integrity
Solution Approach 2:
The patent employs a composite structure combining non-porous plastic material with an aerodynamic profile and closed cavities. This composite approach creates a core that integrates multiple functions: weight reduction through cavity design, strength through non-porous material selection, and manufacturing durability through the robust plastic material properties
2Weight of moving object
If the core is made lighter using foam, then blade mass is reduced, but the core cannot resist forces applied during blade manufacture
Solution Approach 1:
The patent modifies the physical and mechanical parameters of the core material by selecting non-porous plastic material with appropriate density and strength characteristics. This parameter optimization enables the core to maintain reliability during manufacturing while keeping mass reduced through strategic cavity incorporation
Solution Approach 2:
The patent implements an aerodynamic profile shape for the core body with smooth curved surfaces. This geometric optimization not only reduces drag and improves aerodynamic performance but also enhances structural integrity by distributing stresses uniformly, thereby improving reliability during manufacturing operations
3Strength
If a solid core is used to increase resistance to manufacturing forces, then the core becomes stronger, but the blade mass increases
Solution Approach 1:
The patent segments the core interior by introducing closed cavities within the non-porous plastic material. This segmentation strategy maintains the external structural integrity and strength needed for manufacturing while removing internal material that would contribute to mass, thereby achieving strength without proportional weight increase
Solution Approach 2:
The patent applies different material densities locally within the core structure by incorporating closed cavities in specific regions. The non-porous plastic material provides strength where needed, while the cavities reduce mass in regions where full material density is not required, optimizing the local quality distribution to balance strength and weight
Data Source
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AI summary
A vane (46) for a turbine engine comprises a body (54) in the shape of an airfoil formed of a shell (56) made of a composite material formed of a three-dimensional textile of reinforcing fibres consolidated by a hardened resin, the shell forming a pressure surface and a suction surface of the vane which are connected to each other, forming, on one side, a leading edge (64) and, on an opposite side, a trailing edge (66) of the vane, and a core (58) comprising a core body (59) surrounded by the shell (56). The core (58) is made of a non-porous plastic material, and the core body (59) is in the shape of an airfoil and defines at least one closed cavity (68; 68A-68D) of the core (58).