Office Action 1: Notice of Allowance (2025-07-18)

CLAIMS:
CLAIMS What is claimed is:
1\. A turbine engine comprising: a fan having a disk; a turbomachine comprising a compressor section, a combustor in fluid communication with the compressor section, and a turbine section in fluid communication with the combustor; a speed reduction device driven by the turbine section and configured for rotating the fan; and composite airfoils comprising at least one composite fan blade and at least one composite outlet guide vane downstream from the at least one composite fan blade; wherein the at least one composite fan blade comprises: a composite body extending chordwise from a body leading edge to a body trailing edge and extending spanwise between a base and a tip; a root extending from the base of the composite body and coupled to the disk; and a leading edge protector having a protector leading edge different from, and receiving at least a portion of, the body leading edge, the leading edge protector including a projection that extends over at least a portion of the root and contacts the disk, and wherein the projection is configured to transfer impact force to the disk; wherein a leading length (LL) extends chordwise from the protector leading edge to an end of the leading edge protector, and a chord length (CL) extends chordwise from the protector leading edge to the body trailing edge; and wherein the leading length (LL) is related to the chord length (CL) by an airfoil protection factor (APF) = LLCL; and a first APF (APF1) for the at least one composite fan blade is greater than or equal to 0.2 and less than or equal to 0.30 (0.2 ≤ APF1 ≤ 0.3) and a second APF (APF2) for the at least one composite outlet guide vane is greater than or equal to 0.08 and less than or equal to 0.17 (0.08 ≤ APF2 ≤ 0.17).
2\. The turbine engine of claim 1, wherein APF1 relates to APF2 by an expression: APF1APF2 to define a stage protection factor (SPF), and wherein the SPF is greater than or equal to 0.7 and less than or equal to 4 (0.7 ≤ SPF ≤ 4).
3\. The turbine engine of claim 2, wherein the SPF is greater than or equal to 0.95 and less than or equal to 2.5 (0.95 ≤ SPF ≤ 2.5).
4\. The turbine engine of claim 1, wherein a bypass ratio is from 10:1 to 22:1.
5\. The turbine engine of claim 1, wherein the projection provides a reduction in local peak stresses as compared to without the projection.
6\. The turbine engine of claim 1, wherein the projection is coupled to the disk.
7\. The turbine engine of claim 6, wherein the projection is spaced from the root.
8\. The turbine engine of claim 1, wherein the projection is positioned between the disk and the root.
9\. The turbine engine of claim 1, wherein the leading edge protector includes a first wall adjacent a suction sidewall of the composite body, a second wall adjacent a pressure sidewall of the composite body, and a third wall interconnecting the first wall and the second wall, and wherein the projection includes a first projection formed by the first wall and extending over a first portion of the root and a second projection formed by the second wall and extending over a second portion of the root.
10\. The turbine engine of claim 1, wherein the speed reduction device is a power gearbox.
11\. The turbine engine of claim 1, wherein the composite body is a polymer matrix composite (PMC).
12\. The turbine engine of claim 11, wherein the leading edge protector is a metallic leading edge protector.

OFFICE ACTION:
DETAILED ACTION
The present application, filed on or after March 16, 2013, is being examined under the first inventor to file provisions of the AIA .
This action is in response to the claims filed 4/23/2025.
Claims 1-12 are presented for examination.
Information Disclosure Statement
The information disclosure statement (IDS) submitted on 4/23/2025 is in compliance with the provisions of 37 CFR 1.97.  Accordingly, the information disclosure statement is being considered by the examiner.
Allowable Subject Matter
Claims 1-12 allowed.
The following is an examiner’s statement of reasons for allowance.
The prior art of record, either alone or combination, is silent to each and every limitation required of claim 1.
The prior art of record discloses various analogous turbine engines comprising composite airfoils with leading edge protectors that have particular shapes and relative dimensions to the airfoils upon which they are mounted.  However, none of the art of record discloses or suggests the particularly claimed airfoil protection factors and leading edge protector projection extension over a fan blade root to contact a disk and configured to transfer impact force as well as each and every other limitation required of claim 1.  Claims 2-12 depend on claim 1.
Any comments considered necessary by applicant must be submitted no later than the payment of the issue fee and, to avoid processing delays, should preferably accompany the issue fee.  Such submissions should be clearly labeled “Comments on Statement of Reasons for Allowance.”
Conclusion



CITED REFERENCE SUMMARIES: Ref US20150377030A1: Claims:
A sheath for an airfoil, the sheath comprising: a solid member forming an outer edge, the outer edge including a main portion and a projecting portion, the projecting portion having a variable dimension; a pressure side flank, the pressure surface side flank projecting from the solid member opposite the outer edge; a suction side flank, the suction side flank projecting from the solid member opposite the outer edge, the pressure side flank and the suction side flank forming a receiving cavity.
a solid member forming an outer edge, the outer edge including a main portion and a projecting portion, the projecting portion having a variable dimension;
a pressure side flank, the pressure surface side flank projecting from the solid member opposite the outer edge;
a suction side flank, the suction side flank projecting from the solid member opposite the outer edge, the pressure side flank and the suction side flank forming a receiving cavity.
The sheath of claim 1 , wherein the main portion includes a uniform dimension, measured from the outer edge of the solid member to a flank edge of the pressure side flank.
The sheath of claim 1 , wherein the variable dimension of the projecting portion, as measured from the outer edge of the solid member to a flank edge of the pressure side flank, varies in dimension taken along a span-wise direction.
The sheath of claim 1 , wherein the pressure side flank includes a dimension which covers a minimum section of a pressure surface side of the airfoil.
The sheath of claim 1 , wherein the suction side flank includes a dimension which covers a minimum section of a suction surface side of the airfoil.
The sheath of claim 2 , wherein the projecting portion is adjacent to the uniform portion, the variable dimension gradually increases as measured along the span-wise direction away from the uniform portion.
An airfoil for a gas turbine engine, the airfoil comprising: a leading edge; a pressure surface side; a suction surface side; and a sheath including a solid member, a pressure side flank and a suction side flank, the solid member forming an outer edge, the outer edge including a main portion and a projecting portion, the projecting portion having a variable dimension, the pressure side flank projecting from the solid member opposite the outer edge, the suction side flank projecting from the solid member opposite the outer edge, the pressure side flank and the suction side flank forming a receiving cavity for receiving the leading edge, the pressure side flank secured to the pressure surface side, the suction side flank secured to the suction surface side.
a pressure surface side;
a suction surface side; and
a sheath including a solid member, a pressure side flank and a suction side flank, the solid member forming an outer edge, the outer edge including a main portion and a projecting portion, the projecting portion having a variable dimension, the pressure side flank projecting from the solid member opposite the outer edge, the suction side flank projecting from the solid member opposite the outer edge, the pressure side flank and the suction side flank forming a receiving cavity for receiving the leading edge, the pressure side flank secured to the pressure surface side, the suction side flank secured to the suction surface side.
The airfoil as claimed in claim 7 , wherein the main portion includes a uniform dimension, measured from the outer edge of the solid member to a flank edge of the pressure side flank.
The airfoil as claimed in claim 7 , wherein the variable dimension of the projecting portion, as measured from the outer edge of the solid member to a flank edge of the pressure side flank, varies in dimension taken along a span-wise direction of the airfoil.
The airfoil as claimed in claim 7 , wherein the pressure side flank includes a dimension which covers a minimum section of the pressure surface side of the airfoil.
The airfoil as claimed in claim 7 , wherein the suction side flank includes a dimension which covers a minimum section of a suction surface side of the airfoil.
The airfoil as claimed in claim 8 , wherein the projecting portion is adjacent to the uniform portion, the variable dimension gradually increases as measured in the span-wise direction moving away from the uniform portion.
The airfoil as claimed in claim 7 , wherein the pressure side flank is secured to the pressure surface side by an epoxy adhesive and the suction side flank is secured to the suction surface side by an epoxy adhesive.
The airfoil as claimed in claim 7 , wherein the airfoil is manufactured from aluminum.
The airfoil as claimed in claim 7 , where in the sheath is manufactured from titanium.
A method of protecting a leading edge of an airfoil, comprising: forming a sheath to include a solid member, an outer edge with a projecting portion and a main portion, a pressure side flank, and a suction side flank, the projecting portion adjacent to the main portion, the projecting portion having a variable dimension; and securing the sheath to the airfoil having a tip, a root, a pressure surface side, a suction surface side, and a trailing edge, the pressure side flank secured to the pressure surface side of the airfoil and the suction side flank secured to the suction surface side of the airfoil.
forming a sheath to include a solid member, an outer edge with a projecting portion and a main portion, a pressure side flank, and a suction side flank, the projecting portion adjacent to the main portion, the projecting portion having a variable dimension; and
securing the sheath to the airfoil having a tip, a root, a pressure surface side, a suction surface side, and a trailing edge, the pressure side flank secured to the pressure surface side of the airfoil and the suction side flank secured to the suction surface side of the airfoil.
The method of claim 16 , wherein forming the sheath includes forming the projecting portion so that the variable dimension gradually increases as measured along a span-wise direction moving away from the main portion.
The method of claim 16 , wherein forming the sheath includes forming the pressure side flank so that a dimension of the pressure side flank covers a minimum section of the pressure surface side of the airfoil.
The method of claim 16 , wherein forming the sheath includes forming the suction side flank so that a dimension of the suction side flank covers a minimum section of the suction surface side of the airfoil.
The method of claim 17 , wherein forming the sheath includes forming the main portion so that the main portion may have a uniform dimension that is uniform as measured along a span-wise direction moving away from the projecting portion.
Ref US20210388726A1: Claims:
A method of manufacturing a component for a gas turbine engine, the method comprising: applying a thermoplastic polymer sheet over a composite body for the component; applying a shield over part of the composite body, the shield terminating at an end which overlies the thermoplastic polymer sheet and defines an interface between shielded and unshielded regions of the component; and pressing the shield into the thermoplastic polymer sheet so that the thermoplastic polymer sheet deforms around the end of the shield, such that an exterior profile of the component at the interface between the shielded and unshielded regions is flush.
applying a thermoplastic polymer sheet over a composite body for the component;
applying a shield over part of the composite body, the shield terminating at an end which overlies the thermoplastic polymer sheet and defines an interface between shielded and unshielded regions of the component; and
pressing the shield into the thermoplastic polymer sheet so that the thermoplastic polymer sheet deforms around the end of the shield, such that an exterior profile of the component at the interface between the shielded and unshielded regions is flush.
The method according to claim 1 comprising: pressing the shield into the thermoplastic polymer sheet so that the thermoplastic polymer sheet deforms around the end of the shield such that the thermoplastic polymer sheet has a discontinuous thickness at the end of the shield.
pressing the shield into the thermoplastic polymer sheet so that the thermoplastic polymer sheet deforms around the end of the shield such that the thermoplastic polymer sheet has a discontinuous thickness at the end of the shield.
The method according to claim 2 comprising: pressing the shield into the thermoplastic polymer sheet so that the thermoplastic polymer sheet deforms around the end of the shield such that the thickness of the thermoplastic polymer sheet ( 43 ) between the shield and the composite body is reduced relative to the thickness of the thermoplastic polymer sheet in the unshielded region.
pressing the shield into the thermoplastic polymer sheet so that the thermoplastic polymer sheet deforms around the end of the shield such that the thickness of the thermoplastic polymer sheet ( 43 ) between the shield and the composite body is reduced relative to the thickness of the thermoplastic polymer sheet in the unshielded region.
The method according to claim 1 comprising: pressing the shield into the thermoplastic polymer sheet using a tool which defines a profile for the component.
pressing the shield into the thermoplastic polymer sheet using a tool which defines a profile for the component.
The method according to claim 1 , wherein the thermoplastic polymer sheet comprises thermoplastic polyurethane.
The method according to claim 1 , wherein the shield is a metal shield.
The method according to claim 1 , wherein the end of the shield is chamfered.
The method according to claim 1 further comprising: applying adhesive between the thermoplastic polymer sheet and the composite body; and/or applying adhesive between the shield and the composite body and/or the thermoplastic polymer sheet.
applying adhesive between the thermoplastic polymer sheet and the composite body; and/or
applying adhesive between the shield and the composite body and/or the thermoplastic polymer sheet.
The method according to claim 8 , wherein the adhesive is supported by a scrim material.
The method according to claim 1 , wherein the component is a fan blade or a guide vane and the composite body is a composite fan blade body or a composite guide vane body, wherein the composite fan blade body or the composite guide vane body comprises a pressure surface and a suction surface, each extending between a leading edge and a trailing edge, and wherein the method comprises: applying the shield over the leading edge and/or the trailing edge.
applying the shield over the leading edge and/or the trailing edge.
The method according to claim 1 , wherein the component is a nose cone, the composite body is a composite nose cone body, and the method comprises: applying the shield over an apex of the composite nose cone body.
applying the shield over an apex of the composite nose cone body.
A component for a gas turbine engine manufactured according to a method comprising: applying a thermoplastic polymer sheet over a composite body for the component; applying a shield over part of the composite body, the shield terminating at an end which overlies the thermoplastic polymer sheet and defines an interface between shielded and unshielded regions of the component; and pressing the shield into the thermoplastic polymer sheet so that the thermoplastic polymer sheet deforms around the end of the shield, such that an exterior profile of the component at the interface between the shielded and unshielded regions is flush.
A component for a gas turbine engine, the component comprising: a composite body; a thermoplastic polymer layer extending over the composite body; and at least one shield extending over part of the composite body, the or each shield terminating at an end which overlies the thermoplastic polymer layer and defines an interface between a respective shielded region and an unshielded region of the component, an exterior profile of the component at the or each interface between the shielded and unshielded regions being flush; wherein at the end of the or each shield, the thermoplastic polymer layer has a discontinuous thickness, the thickness of the thermoplastic polymer layer between the shield and the composite body in the respective shielded region being lower than the thickness of the thermoplastic polymer layer in the unshielded region; and wherein the thermoplastic polymer layer covers a remainder of the composite body not covered by any of the at least one shield.
a composite body;
a thermoplastic polymer layer extending over the composite body; and
at least one shield extending over part of the composite body, the or each shield terminating at an end which overlies the thermoplastic polymer layer and defines an interface between a respective shielded region and an unshielded region of the component, an exterior profile of the component at the or each interface between the shielded and unshielded regions being flush;
wherein at the end of the or each shield, the thermoplastic polymer layer has a discontinuous thickness, the thickness of the thermoplastic polymer layer between the shield and the composite body in the respective shielded region being lower than the thickness of the thermoplastic polymer layer in the unshielded region; and
wherein the thermoplastic polymer layer covers a remainder of the composite body not covered by any of the at least one shield.
The component according to claim 13 , wherein the component is a fan blade or a guide vane and the composite body is a composite fan blade body or a composite guide vane body, the fan blade or the guide vane comprising a pressure surface and a suction surface, each extending between a leading edge and a trailing edge, and the or each shield extending over the leading edge and/or the trailing edge.
The component according to claim 13 , wherein the component is a nose cone and the composite body is a composite nose cone body, a shield of the at least one shield extending over an apex of the nose cone body.
Ref US20200157953A1: Claims:
A blade for a propulsion apparatus, comprising: a body formed of a composite material having opposed pressure and suction sides, and extending in span between a root and a tip, and extending in chord between a leading edge and a trailing edge; the body defining a body tip surface; a protective cover extending from near the tip of the blade toward the root of the blade along the leading edge and the trailing edge of the body; the protective cover defining a protective tip surface; and wherein an abrasive material is adhered to the protective tip surface.
a body formed of a composite material having opposed pressure and suction sides, and extending in span between a root and a tip, and extending in chord between a leading edge and a trailing edge;
the body defining a body tip surface;
a protective cover extending from near the tip of the blade toward the root of the blade along the leading edge and the trailing edge of the body;
the protective cover defining a protective tip surface; and
wherein an abrasive material is adhered to the protective tip surface.
The blade of claim 1 , wherein the body tip surface is substantially free of the abrasive material.
The blade of claim 2 , wherein the protective cover includes a leading edge protector that defines a leading edge tip and the leading edge tip defines at least a portion of the protective tip surface.
The blade of claim 2 , wherein the protective cover includes a tip cap that defines a tip cap edge and the tip cap edge defines at least a portion of the protective tip surface.
The blade of claim 2 , wherein the protective cover includes a leading edge protector that defines a leading edge tip and a tip cap the defines a tip cap edge and together the leading edge tip and the tip cap edge define the protective tip surface.
The blade of claim 5 , wherein the body tip surface defines a plane and the protective tip surface is substantially coplanar with the body tip surface.
The blade of claim 5 , wherein the body tip surface defines a plane and the protective cover extends away from the root of the blade beyond the plane of the body tip surface.
The blade of claim 5 , wherein the body tip surface defines a plane and the protective tip surface of the protective cover is positioned between the plane of the body tip surface and the root.
A gas turbine engine apparatus, comprising: a turbomachinery core; a fan coupled in driven relationship with the turbomachinery core, the fan including: a plurality of blades positioned around a disk, each blade including: an airfoil body comprising composite materials and having opposed pressure and suction sides, and extending in span between a root and a tip, and extending in chord between a leading edge and a trailing edge; the airfoil body defining a body tip surface; a protective cover extending from near the tip toward the root; the protective cover defining a protective tip surface; and wherein an abrasive material is adhered to the protective tip surface.
a turbomachinery core;
a fan coupled in driven relationship with the turbomachinery core, the fan including:
a plurality of blades positioned around a disk, each blade including:
an airfoil body comprising composite materials and having opposed pressure and suction sides, and extending in span between a root and a tip, and extending in chord between a leading edge and a trailing edge;
the airfoil body defining a body tip surface;
a protective cover extending from near the tip toward the root;
The apparatus of claim 9 , wherein the body tip surface is substantially free of the abrasive material.
The apparatus of claim 10 , wherein the protective cover includes a leading edge protector that defines a leading edge tip and the leading edge tip defines at least a portion of the protective tip surface.
The apparatus of claim 10 , wherein the protective cover includes a tip cap that defines a tip cap edge and the tip cap edge defines at least a portion of the protective tip surface.
The apparatus of claim 10 , wherein the protective cover includes a leading edge protector that defines a leading edge tip and a tip cap the defines a tip cap edge and together the leading edge tip and the tip cap edge define the protective tip surface.
The apparatus of claim 13 , wherein the body tip surface defines a plane and the protective tip surface is substantially coplanar with the body tip surface.
The apparatus of claim 13 , wherein the body tip surface defines a plane and the protective cover extends away from the root of the blade beyond the plane of the body tip surface.
The apparatus of claim 13 , wherein the body tip surface defines a plane and the protective tip surface of the protective cover is positioned between the plane of the body tip surface and the root.
A propulsor configured for tight relative clearances, the propulsor comprising: a blade; a shroud that includes an abradable portion; the blade including a body having a body tip surface positioned near the abradable portion of the shroud; the blade including a leading edge and a trailing edge; a leading edge protector extending along the body from near the body tip surface of the blade away from the shroud; a tip cap extending along the body from near the body tip surface of the blade away from the shroud; the leading edge protector and the tip cap define an edge surface; and an adhesive material configured to abrade the abradable portion of the shroud is adhered to the edge surface.
a shroud that includes an abradable portion;
the blade including a body having a body tip surface positioned near the abradable portion of the shroud;
the blade including a leading edge and a trailing edge;
a leading edge protector extending along the body from near the body tip surface of the blade a
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