Ultrasonic Stitching of Composite Fan Blades

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Solution Overview

Problem

Composite fan blades made from laminated materials often delaminate under extreme loading due to high shear strains, and existing stitching methods can damage the material, affecting its mechanical properties.

Innovation Solution

A method and system for ultrasonically stitching composite materials using a guide to form an augmented surface, with reinforcing elements extending through the composite body in a combination of perpendicular and oblique stitches to enhance strength and durability without damaging the material.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If layers are stitched together to prevent delamination, then strength and durability are improved, but mechanical properties may be damaged or altered

Engineering Contradiction:

Improvestrength and durabilityVSAvoidmechanical property integrity

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent replaces conventional mechanical stitching methods with ultrasonic stitching technology. The ultrasonic stitching device uses high-frequency vibrations to fuse layers together without mechanical penetration, thereby preventing delamination while avoiding damage to the mechanical properties of the composite material.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the physical state and parameters of the stitching process by using ultrasonic vibrations at specific frequencies and amplitudes. This allows the reinforcing elements to be bonded to layers without mechanical penetration, resolving the contradiction between achieving strong bonds and preserving material integrity.

Inventive Principle:

Principle #35Parameter changes

2Strength

If metal fan blades are used for strength, then durability is improved, but weight increases reducing fuel efficiency

Engineering Contradiction:

ImprovedurabilityVSAvoidweight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent uses composite materials consisting of multiple layers bonded together with ultrasonic stitching. This composite structure provides the necessary strength and durability to replace metal fan blades while significantly reducing weight, thereby improving fuel efficiency.

Inventive Principle:

Principle #40Composite materials

3Stability of the object's composition

If conventional stitching methods are used to reinforce layers, then delamination is prevented, but material damage occurs

Engineering Contradiction:

Improvelayer bondingVSAvoidmaterial damage

Core Design Contradiction:

Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

The patent replaces mechanical stitching that penetrates and damages material with ultrasonic stitching that uses vibration-based fusion. This substitution prevents delamination while avoiding the material damage caused by conventional mechanical stitching methods.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution effectively increases the strength and durability of composite materials, enabling them to withstand high shear strains while maintaining a lightweight structure, thus improving fuel efficiency by reducing material weight.

Implementation Method 1

Methods and systems for ultrasonically stitching composite materials

Methodology Applied

Scientific EffectUltrasonic vibration: Ultrasonic Vibration

Data Source

PatentUS8939099B2Methods and systems for stitching composite materials

Publication Date: 2015.01.27 GENERAL ELECTRIC CO

AI summary

A composite material includes a composite body having a composite surface, and a reinforcing element extending through the composite body in a first plurality of stitches and a second plurality of stitches. The first plurality of stitches are aligned relative to the composite surface substantially similarly to each other. The second plurality of stitches are aligned relative to the composite surface substantially dissimilarly to each other.