초록 ▼

The present invention provides a turbofan engine including leading edge erosion protection for composite stator vanes contained therein. The composite stator vanes are defined by a leading edge, a trailing edge, a concave surface and a convex surface. The vanes are generally formed of a graphite fi

The present invention provides a turbofan engine including leading edge erosion protection for composite stator vanes contained therein. The composite stator vanes are defined by a leading edge, a trailing edge, a concave surface and a convex surface. The vanes are generally formed of a graphite fiber and an aramid fiber braided preform that is laminated with an epoxy matrix resin or other high temperature matrix resin. A wire mesh screen is embedded during a molding process into an outermost surface of the leading edge of the epoxy matrix resin. A tapering erosion protection layer comprised of an erosion protective material is applied to the wire mesh screen at the leading edge of the composite stator vane an aids in protecting the leading edge of the stator vane from debris and contaminants, including operational fluids, dust, and sand that may be carried in an air stream passing therethrough the turbofan engine, as well as an erosive operational environment.

대표청구항 ▼

What is claimed is: 1. A turbofan engine comprising: a turbofan rotor positioned to direct intake air therethrough; a gas turbine core engine disposed downstream of the turbofan rotor and comprising a compressor, a combustor and a turbine; and a plurality of composite stator vanes disposed between

What is claimed is: 1. A turbofan engine comprising: a turbofan rotor positioned to direct intake air therethrough; a gas turbine core engine disposed downstream of the turbofan rotor and comprising a compressor, a combustor and a turbine; and a plurality of composite stator vanes disposed between the turbofan rotor and the gas turbine core engine, and configured to receive air directed through the turbofan rotor and direct the received intake air into the gas turbine engine core, each of the composite stator vanes is defined by a leading edge, a trailing edge, a concave surface and a convex surface, and each of the composite stator vanes comprises: an epoxy matrix resin; an epoxy matrix resin composite wound and twisted preform comprised of a plurality of braided graphite fibers and aramid fibers embedded in the epoxy matrix resin; a wire mesh screen molded into the leading edge of the composite stator vane and embedded into the epoxy matrix resin whereby a portion of the epoxy matrix resin is extruded through the wire mesh screen to an external surface of the wire mesh screen; and an erosion protection layer disposed on the wire mesh screen and portions of the epoxy matrix resin extruded through the wire mesh screen. 2. A turbofan engine as claimed in claim 1, wherein the wire mesh screen is molded into the leading edge of the composite stator vane and wherein the wire mesh screen has a trailing edge located in a range of about 0.1 to 0.5 inches from the leading edge of the composite stator vane. 3. A turbofan engine as claimed in claim 2, wherein the wire mesh screen has a trailing edge located about 0.3 inches from the leading edge of the composite stator vane. 4. A turbofan engine as claimed in claim 1, wherein the wire mesh screen has between about 100 and 150 wires per square inch. 5. A turbo fan engine as claimed in claim 4, wherein the wire mesh screen has 120 wires per square inch. 6. A turbofan engine as claimed in claim 1, wherein the erosion protection layer has a thickness of up to 0.010". 7. A turbofan engine as claimed in claim 6, wherein the erosion protection layer has a thickness in the range of 0.001 to 0.005 inches. 8. A turbofan engine as claimed in claim 7, wherein the erosion protection layer has a thickness of 0.003 inches and tapers to zero at a trailing edge of the wire mesh screen. 9. A turbofan engine as claimed in claim 1, wherein the erosion protection layer is formed of at least one of the following materials: tungsten carbide, tungsten carbide-cobalt, cobalt, molybdenum, titanium carbide-nickel, chromium oxide, a high quality plasma sprayed erosion resistant bondcoat or top coat. 10. A turbofan engine as claimed in claim 9, wherein the erosion protection layer is formed of a plasma sprayed Co60 Mo28 Cr8.5 Si2.5 Ni1.5 alloy T400 coating. 11. A composite stator vane comprising: a graphite fiber and an aramid fiber wound and twisted preform laminated with a matrix resin, wherein the composite stator vane is defined by a leading edge, a trailing edge, a concave surface and a convex surface; a wire mesh screen embedded into an outermost surface of the leading edge of the epoxy matrix resin and whereby a portion of the epoxy matrix resin is extruded through the wire mesh screen to an external surface of the wire mesh screen; and an erosion protection layer comprised of an erosion protective material applied to the wire mesh screen and the portions of the epoxy matrix resin extruded through the wire mesh screen at the leading edge of the composite stator vane. 12. A composite stator vane as claimed in claim 11, wherein the wire mesh screen has a trailing edge located in a range of 0.1 to 0.5 inches from the leading edge of the composite stator vane. 13. A composite stator vane as claimed in claim 12, wherein the wire mesh screen has a trailing edge located 0.3 inches from the leading edge of the composite stator vane. 14. A composite stator vane as claimed in claim 11, wherein the erosion protection layer has a thickness of up to 0.010". 15. A composite stator vane as claimed in claim 11, wherein the erosion protection layer has a thickness in the range of 0.001 to 0.005 inches and tapers to zero at a trailing edge of the wire mesh screen. 16. A composite stator vane as claimed in claim 11, wherein the erosion protection layer is formed of at least one of the following materials: tungsten carbide, tungsten carbide-cobalt, titanium carbide-nickel, chromium oxide, and a high quality plasma sprayed erosion resistant bondcoat or top coat. 17. A composite stator vane as claimed in claim 16, wherein the erosion protection layer is formed of a plasma sprayed Co60 Mo28 Cr8.5 Si2.5 Ni1.5 alloy coating. 18. A composite stator vane defined by a leading edge, a trailing edge, a concave surface and a convex surface, the composite stator vane comprising: a graphite fiber and an aramid fiber wound and twisted preform laminated with an epoxy matrix resin; a wire mesh screen embedded into an outermost surface of the epoxy matrix resin at the leading edge of the composite stator vane whereby a portion of the epoxy matrix resin is extruded through the wire mesh screen to an external surface of the wire mesh screen, wherein the wire mesh screen has a trailing edge located in a range of 0.1 to 0.5 inches from the leading edge of the composite stator vane; and an erosion protection layer comprised of an erosion protective material applied to the wire mesh screen and the portions of the epoxy matrix resin extruded through the wire mesh screen, wherein the erosion protection layer tapers from a thickness in a range of 0.001 to 0.005 inches at the leading edge of the composite stator vane to zero at the trailing edge of the wire mesh screen. 19. A composite stator vane as claimed in claim 18, wherein the erosion protection layer is formed of at least one of the following materials: tungsten carbide, tungsten carbide-cobalt, cobalt, molybdenum, titanium carbide-nickel, chromium oxide, a high quality plasma sprayed erosion resistant bondcoat or top coat.