Gas Turbine Vane Honeycomb Core Weight Reduction
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Solution Overview
Problem
Existing gas turbine engine fan exit guide vanes face challenges in efficiently supporting and stabilizing the duct surrounding the fan, particularly in maintaining structural integrity and acoustic performance while minimizing weight and material usage.
Innovation Solution
A gas turbine engine vane design featuring a first member with a suction side and a second member forming the pressure side, including a recess and a core with lower bulk density than the first member, where the second member is secured to the first member with an adhesive, and optionally incorporating a honeycomb core for acoustic benefits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a solid core is used in the vane structure, then structural strength is improved, but weight increases
Solution Approach 1:
The patent applies porous materials by replacing the solid core with a honeycomb core structure. The honeycomb core provides structural strength while significantly reducing weight compared to a solid core, as the cellular structure maintains load-bearing capacity with less material.
Solution Approach 2:
The patent uses composite materials by combining the honeycomb core with adhesive bonding between the first and second members. This composite structure integrates different materials (honeycomb core material, adhesive, and vane shell materials) to achieve optimal strength-to-weight ratio.
2Weight of moving object
If material density is reduced for weight savings, then weight decreases, but structural integrity deteriorates
Solution Approach 1:
The honeycomb core structure serves as a porous material that reduces overall density and weight while maintaining structural integrity through its cellular geometry. The hexagonal cells distribute loads effectively, preventing catastrophic failure.
Solution Approach 2:
The vane is segmented into multiple components (first member, second member, honeycomb core, adhesive layers) that work together. This segmentation allows each component to be optimized for its specific function while contributing to overall structural integrity.
3Ease of manufacture
If adhesive bonding is used to join members, then manufacturing complexity is reduced, but joint strength may be insufficient
Solution Approach 1:
The adhesive bonding creates a composite structure where the adhesive layer bonds the first and second members together. This composite approach simplifies manufacturing compared to mechanical fastening while achieving sufficient joint strength through proper adhesive selection and application.
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 design enhances structural support and acoustic damping while reducing material density, improving the engine's efficiency and durability by providing a lightweight yet robust vane configuration that effectively holds the duct in place.
Implementation Method 1
The second member is secured to the first member with an adhesive
Implementation Method 2
optionally incorporating a honeycomb core for acoustic benefits
Data Source
AI summary
A gas turbine engine vane has first and second members. The first member has a first surface section forming a suction side of an airfoil of the vane. The second surface section forms leading and trailing portions of a pressure side of the airfoil. The third surface section forms a recess between the leading and trailing portions. The second member is secured to the first member and has a first surface section forming an intermediate portion of the pressure side a leading protrusion of the second member may be captured by a recess below a lip of the first member.