Abstract:
One embodiment of the present invention is a unique vane system. Another embodiment is a unique gas turbine engine. Another embodiment is a unique method for manufacturing a bypass vane stage. Other embodiments include apparatuses, systems, devices, hardware, methods, and combinations for turbine engines and vane systems for turbine engines. Further embodiments, forms, features, aspects, benefits, and advantages of the present application will become apparent from the description and figures provided herewith.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    The present application claims benefit of U.S. Provisional Patent Application No. 61/581,786 filed Dec. 30, 2011, entitled TURBINE ENGINE AND VANE SYSTEM, which is incorporated herein by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to turbine engines, and more particularly, to vane systems for turbine engines. 
       BACKGROUND 
       [0003]    Vane systems for turbine engines that are cost effective and readily manufactured, such as bypass vane systems for turbofan engines, remain an area of interest. Some existing systems have various shortcomings, drawbacks, and disadvantages relative to certain applications. Accordingly, there remains a need for further contributions in this area of technology. 
       SUMMARY 
       [0004]    One embodiment of the present invention is a unique vane system. Another embodiment is a unique gas turbine engine. Another embodiment is a unique method for manufacturing a bypass vane stage. Other embodiments include apparatuses, systems, devices, hardware, methods, and combinations for turbine engines and vane systems for turbine engines. Further embodiments, forms, features, aspects, benefits, and advantages of the present application will become apparent from the description and figures provided herewith. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0005]    The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and wherein: 
           [0006]      FIG. 1  schematically illustrates some aspects of a non-limiting example of a gas turbine engine in accordance with an embodiment of the present invention. 
           [0007]      FIG. 2  illustrates some aspects of a non-limiting example of a bypass vane doublet in accordance with an embodiment of the present invention. 
           [0008]      FIG. 3  illustrates some aspects of a non-limiting example of a bypass vane in accordance with an embodiment of the present invention. 
           [0009]      FIGS. 4A-4D  illustrate some aspects of non-limiting examples of vane platform segments in accordance with an embodiment of the present invention. 
           [0010]      FIGS. 5A and 5B  illustrate some aspects of non-limiting examples of vane platform segments in accordance with embodiments of the present invention. 
           [0011]      FIG. 6  schematically illustrates some aspects of a non-limiting example of a vane platform in accordance with an embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0012]    For purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings, and specific language will be used to describe the same. It will nonetheless be understood that no limitation of the scope of the invention is intended by the illustration and description of certain embodiments of the invention. In addition, any alterations and/or modifications of the illustrated and/or described embodiment(s) are contemplated as being within the scope of the present invention. Further, any other applications of the principles of the invention, as illustrated and/or described herein, as would normally occur to one skilled in the art to which the invention pertains, are contemplated as being within the scope of the present invention. 
         [0013]    Referring to the drawings, and in particular  FIG. 1 , a non-limiting example of some aspects of a gas turbine engine  10  in accordance with an embodiment of the present invention is schematically depicted. In one form, gas turbine engine  10  is an aircraft propulsion power plant. In other embodiments, gas turbine engine  10  may be a land-based or marine engine. In one form, gas turbine engine  10  is a multi-spool turbofan engine. In other embodiments, gas turbine engine  10  may take other forms, and may be, for example, a turboshaft engine, a turbojet engine, a turboprop engine, or a combined cycle engine having a single spool or multiple spools. 
         [0014]    As a turbofan engine, gas turbine engine  10  includes a fan  12 , a bypass duct  14 , a compressor  16 , a diffuser  18 , a combustor  20 , a turbine  22 , a discharge duct  26  and a nozzle system  28 . Bypass duct  14  and compressor  16  are in fluid communication with fan system  12 . Diffuser  18  is in fluid communication with compressor  16 . Combustor  20  is fluidly disposed between compressor  16  and turbine  22 . In one form, combustor  20  includes an annular combustion liner (not shown in  FIG. 1 ) that contains a continuous combustion process. In other embodiments, combustor  20  may take other forms, and may be, for example and without limitation, a can combustor or a canannular combustor. In still other embodiments, combustor  20  may be a deflagration combustion system and/or a detonation combustion system. 
         [0015]    Fan  12  includes a fan rotor system  30  having a plurality of blades. In various embodiments, fan rotor system  30  includes one or more rotors (not shown) that are powered by turbine  22 . Bypass duct  14  is operative to transmit a bypass flow generated by fan system  12  to nozzle  28 . Compressor  16  includes a compressor rotor system  32 . In various embodiments, compressor rotor system  32  includes one or more rotors (not shown) that are powered by turbine  22 . Each compressor rotor includes a plurality of rows compressor blades (not shown) that are alternatingly interspersed with rows of compressor vanes (not shown). Turbine  22  includes a turbine rotor system  34 . In various embodiments, turbine rotor system  34  includes one or more rotors (not shown) operative to drive fan rotor system  30  and compressor rotor system  32 . Each turbine rotor includes a plurality of turbine blades (not shown) that are alternatingly interspersed with rows of turbine vanes (not shown). 
         [0016]    Turbine rotor system  34  is drivingly coupled to compressor rotor system  32  and fan rotor system  30  via a shafting system  36 . In various embodiments, shafting system  36  includes a plurality of shafts that may rotate at the same or different speeds and directions. In some embodiments, only a single shaft may be employed. Turbine  22  is operative to discharge an engine  10  core flow to nozzle  28 . 
         [0017]    In one form, fan rotor system  30 , compressor rotor system  32 , turbine rotor system  34  and shafting system  36  rotate about an engine centerline  48 . In other embodiments, all or parts of fan rotor system  30 , compressor rotor system  32 , turbine rotor system  34  and shafting system  36  may rotate about one or more other axes of rotation in addition to or in place of engine centerline  48 . 
         [0018]    Discharge duct  26  extends between a discharge portion  40  of turbine  22  and engine nozzle  28 . Discharge duct  26  is operative to direct bypass flow and core flow from a bypass duct discharge portion  38  and turbine discharge portion  40 , respectively, into nozzle  28 . In some embodiments, discharge duct  26  may be considered a part of nozzle  28 . Nozzle  28  is in fluid communication with fan system  12  and turbine  22 . Nozzle  28  is operative to receive the bypass flow from fan system  12  via bypass duct  14 , and to receive the core flow from turbine  22 , and to discharge both as an engine exhaust flow, e.g., a thrust-producing flow. In other embodiments, other nozzle arrangements may be employed, including separate nozzles for each of the core flow and the bypass flow. 
         [0019]    During the operation of gas turbine engine  10 , air is drawn into the inlet of fan  12  and pressurized by fan  12 . Some of the air pressurized by fan  12  is directed into compressor  16  as core flow, and some of the pressurized air is directed into bypass duct  14  as bypass flow, which is discharged into nozzle  28  via discharge duct  26 . Compressor  16  further pressurizes the portion of the air received therein from fan  12 , which is then discharged into diffuser  18 . Diffuser  18  reduces the velocity of the pressurized air, and directs the diffused core airflow into combustor  20 . Fuel is mixed with the pressurized air in combustor  20 , which is then combusted. The hot gases exiting combustor  20  are directed into turbine  22 , which extracts energy in the form of mechanical shaft power sufficient to drive fan  12  and compressor  16  via shafting system  36 . The core flow exiting turbine  22  is directed along an engine tail cone  42  and into discharge duct  26 , along with the bypass flow from bypass duct  14 . Discharge duct  26  is configured to receive the bypass flow and the core flow, and to discharge both into nozzle  28  as an engine exhaust flow, e.g., for providing thrust, such as for aircraft propulsion. 
         [0020]    Disposed within bypass duct  14  is a bypass vane stage  50  and a plurality of struts  52 . In one form, bypass vane stage  50  is disposed proximate to fan blade stage  12 , and is operative to direct air from fan  12 . In other embodiments, bypass vane stage  50  may be disposed to direct air into fan  12  blades. In one form, struts  52  are located downstream of vane stage  50 . In other embodiments, struts  52  may be located upstream of vane stage  50  in addition to or in place of being located downstream of vane stage  50 . Bypass vane stage  50  is configured to straighten the pressurized air flow generated by fan  12  and to direct it into bypass duct  14 . In one form, struts  52  are configured to transmit engine  10  loads from engine  10  to the aircraft into which engine  10  is installed, e.g., into nacelle and/or wing structures. In other embodiments, struts  52  may not be configured to transmit engine  10  loads to the aircraft. 
         [0021]    In one form, bypass vane stage  50  includes a circumferential tip platform  54 , a circumferential hub platform  56  spaced radially inward of circumferential tip platform  54 , and a plurality of bypass vanes  58 . Circumferential tip platform  54  and circumferential hub platform  56  each include a plurality of openings. In one form, the openings correspond in number to the number bypass vanes  58 , and are configured to receive respective portions of the vanes. In other embodiments, the number of openings may be different, e.g., depending upon the construction of vanes  58 . In one form, vanes  58  are mounted in the openings and disposed between and attached to circumferential tip platform  54  and circumferential hub platform  56 . Circumferential tip platform  54  and circumferential hub platform  56  are configured to support respective portions of each of the vanes. In one form, vane stage  50  is formed of a composite material, including circumferential tip platform  54 , circumferential hub platform  56  and bypass vanes  58 . In one form, the composite material is carbon fiber with an epoxy resin system. In other embodiments, other composite materials may be employed in addition to or in place of carbon fiber with an epoxy resin system, for example and without limitation, carbon fiber and/or another fiber type with a bismaleimide (BMI) and/or polyimide in addition to or in place of an epoxy resin system. In still other embodiments, still other composite materials may be employed in addition to or in place of those mentioned herein above. In various embodiments, one or more components of vane stage  50 , e.g., circumferential tip platform  54 , circumferential hub platform  56  and/or bypass vanes  58  may be formed from one or more other materials, e.g., metallic, intermetallic, matrix composite and/or other materials in addition to or in place of the composite materials mentioned herein. In one form, each bypass vane  58  is defined by the same dimensions. In other embodiments, bypass vanes  58  may not be defined by the same dimensions. 
         [0022]    In one form, bypass vane stage  50  is formed of a plurality of vane doublets, each doublet having two vanes  58 , a tip platform segment and a hub platform segment. The plurality of vane platform segments, tip and hub, are configured to jointly form circumferential tip platform  54  and circumferential hub platform  56  in the form of two rings, which along with vanes  58  form bypass vane stage  50 . In some embodiments, additional components may be employed, e.g., straps attached to the platform segments and vanes to additionally secure the vanes to the platform segments. Although vane doublets are employed in the present embodiment, it will be understood that singlets, triplets, or vane ring segments having any number of vanes may be employed in other embodiments. 
         [0023]    Referring to  FIG. 2 , some aspects of a non-limiting example of a vane ring segment in the form of a vane doublet  60  are illustrated in accordance with an embodiment of the present invention. Doublet  60  includes two vanes  58 , a vane tip platform segment  62 , a vane hub platform segment  64 , a tip strap  66  and a hub strap  68 . In one form, vanes  58  are formed via a molding process, and each vane  58  is formed to the same dimensions. In other embodiments, other processes may be employed to form vanes  58 ; and vanes  58  may or may not be formed to the same dimensions. In one form, vane tip platform segment  62  and vane hub platform segment  64  are also formed via a molding process. In other embodiments, other processes may be employed to form vane tip platform segment  62  and vane hub platform segment  64 . Vane tip platform segments  62  and vane hub platform segments  64  are configured to be jointly assembled to form rings, which support and position vanes  58 , and which yield circumferential tip platform  54  and circumferential hub platform  56 . Formed into vane tip platform segment  62  and vane hub platform segment  64  are openings configured to receive respective tip and hub portions of vanes  58  and position vanes  58  within doublet  60  and hence vane stage  50 . Vanes  58  are inserted into the openings in vane tip platform segment  62  and vane hub platform segment  64 . Some of the openings vary in position relative to others of the openings so as to preferentially locate vanes  58  at desired locations and setting angles, e.g., to modify airflow through vane stage  50  to accommodate struts  52 , e.g., to direct airflow around struts  52  in order to minimize losses owing to the presence of struts  52 . Hence, in some embodiments, vane  58  locations, e.g., circumferential locations, and setting angles vary as between vanes  58 . 
         [0024]    In one form, vanes  58  are fastened into place in vane tip platform segment  62  and vane hub platform segment  64  using an adhesive. In one form, the adhesive is a paste adhesive. In other embodiments, combinations of paste adhesives, film adhesives and/or foaming adhesives may be employed. Non-limiting examples of paste adhesives include, for example, EC — 2615 and EC — 3448, available from the 3M Corporation of St. Paul, Minn., U.S.A. In other embodiments, other joinery techniques may be employed to attach vanes  58  to vane tip platform segment  62  and vane hub platform segment  64 . In one form, tip and hub straps  66  and  68  are fastened to the ends of vanes  58 , and to vane tip platform segment  62  and vane hub platform segment  64 , respectively using the paste adhesive, to further secure vanes  58  into vane tip platform segment  62  and vane hub platform segment  64 . In other embodiments, other joinery techniques may be employed to further secure tip and hub straps  66  and  68  to vanes  58  and vane tip platform segment  62  and vane hub platform segment  64 . 
         [0025]    Referring to  FIG. 3 , some aspects of a non-limiting example of a vane  58  are depicted in accordance with an embodiment of the present invention. Vane  58  includes an airfoil body  70 , a tip portion  72  and a hub portion  74 . In one form, vane  58  has an airfoil shape  76 , indicated by dashed lines, which may or may not vary as between tip portion  72  and hub portion  74 , depending upon the needs of the particular application. In other embodiments, all or a portion of vane  58  may not include an airfoil shape. Tip portion  72  includes an extension  78  having a lip  80  extending therefrom. In one form, lip  80  extends at a right angle relative to the balance of extension  78 . In other embodiments, lip  80  may be formed as another shape. Hub portion  74  includes an extension  82 . In one form, extensions  78  and  82  are defined by airfoil shape  76 . In other embodiments, one or both of extensions  78  and  82  may have other shapes. Extensions  78  and  82  are configured to be received into openings in vane tip platform segment  62  and vane hub platform segment  64 . 
         [0026]    Referring to  FIGS. 4A-4D , some aspects of non-limiting examples of vane tip platform segment  62  and vane hub platform segment  64  are depicted in accordance with an embodiment of the present invention.  FIGS. 4A and 4B  depict top and sectional views, respectively, of vane tip platform segment  62 , whereas  FIGS. 4C and 4D  depict top and sectional views, respectively, of vane hub platform segment  64 . Vane tip platform segment  62  includes openings  84 . Vane hub platform segment  64  includes openings  86 . Openings  84  and  86  are configured to position vanes  58  within doublet  60  and vane stage  50 . In one form, openings  84  and  86  have the same airfoil cross-sectional shape  76  as body  70  of vane  58 , i.e., the shape of extensions  78  and  82  (and lip  90  for embodiments so equipped). In other embodiments, openings  84  and  86  may take other forms. Each opening  84  is configured to receive a tip portion  72  of a vane  58 , in particular, extension  78  and lip  80 . Lip  80  is configured to retain vane  58  with vane tip platform segment  62 . Openings  84  include a ledge  88 . Ledge  88  is configured to function as a mating surface for the bottom of lip  80  to retain each vane  58  in vane tip platform segment  62 . Each opening  86  is configured to receive a hub portion  74  of a vane  58 , in particular, extension  82 . In one form, vanes  58  are inserted into openings  84  and  86 , in particular, extension  78  and lip  80 , and extension  82 , and are fastened into place using the paste adhesive, and tip and hub straps  66  and  68  are fastened to the ends of vanes  58 , and to vane tip platform segment  62  and vane hub platform segment  64  using the paste adhesive, forming doublets  60 . 
         [0027]    The number of openings  84  and  86  in vane tip platform segment  62  and vane hub platform segment  64  may vary in different embodiments. For example, in vane ring segments in the form of doublet  60 , the number of openings  84  and  86  in vane tip platform segment  62  and vane hub platform segment  64  is sufficient to accommodate two vanes  58  in doublet  60 . For vane ring segments in the forms of singlets or triplets, the number of openings  84  and  86  in vane tip platform segment  62  and vane hub platform segment  64  is sufficient to accommodate a single vane  58  or three vanes  58 , respectively, e.g., as depicted in  FIGS. 5A and 5B  with vane hub platform segments  64 A and  64 B, respectively. The number of openings  84  and  86  in vane tip platform segment  62  and vane hub platform segment  64 , and the number of vanes  58  in each vane ring segment may vary with the needs of the application. The combined number of openings in each of the vane tip platform segments  62  and vane hub platform segments  64  used to form vane stage  50  is selected to be sufficient to accommodate the total number of vanes  58  employed in vane stage  50 . Openings  84  and  86  are formed to vary in one or more of an axial direction  90 , a circumferential direction  92  and a setting angle direction  94 , so that the position of some openings  84  and  86  vary in one or more of axial direction  90 , circumferential direction  92  and setting angle direction  94 , relative to other openings  84  and  86 . In one form, the positions of openings  84  and  86  vary cyclically (in one or more of axial direction  90 , circumferential direction  92  and setting angle direction  94 ) along circumferential direction  92 , e.g., in order to mitigate the effects of struts  52  on bypass airflow, as schematically depicted in  FIG. 6 , which schematically illustrates a plurality of openings  86  in circumferential hub platform  56  formed of a plurality of vane hub platform segments  64 . It will be understood that the variation as between openings  86  illustrated in  FIG. 6 , which includes variation in axial direction  90 , circumferential direction  92  and setting angle direction  94 , is by way of example only, and that the actual variation between openings  86  (and between openings  84 ), which drives the variation between vanes  58 , may vary with the needs of the particular application. 
         [0028]    Embodiments of the present invention include a vane system for a gas turbine engine, comprising: a plurality of vanes, each vane being defined by the same dimensions, wherein each vane includes a first portion and a second portion; a first circumferential vane platform having a plurality of openings corresponding in number to the plurality of vanes, wherein each opening is configured to receive the first portion of one of the vanes; a second circumferential vane platform spaced radially apart from the first circumferential vane platform, wherein the second circumferential vane platform is configured to support the second portion of each of the vanes, wherein some of the plurality of openings vary in position relative to others of the plurality of openings. 
         [0029]    In a refinement, the some of the plurality of openings vary in an axial direction relative to the others of the plurality of openings. 
         [0030]    In another refinement, the some of the plurality of openings vary in a circumferential direction relative to the others of the plurality of openings. 
         [0031]    In yet another refinement, the some of the plurality of openings vary in a setting angle direction relative to the others of the plurality of openings. 
         [0032]    In still another refinement, the some of the plurality of openings vary cyclically in a circumferential direction relative to the others of the plurality of openings. 
         [0033]    In yet still another refinement, the first circumferential vane platform is a ring formed of a plurality of platform segments, each segment including one of the openings. 
         [0034]    In a further refinement, the first circumferential vane platform is a ring formed of a plurality of platform segments, each segment including two of the openings. 
         [0035]    In a yet further refinement, the first circumferential vane platform is a ring formed of a plurality of platform segments, each segment including three of the openings. 
         [0036]    In a still further refinement, the plurality of vanes are formed of a composite material. 
         [0037]    In a yet still further refinement, each vane has a same cross-sectional shape, and wherein each opening has the same cross-sectional shape as each vane. 
         [0038]    Embodiments of the present invention include a gas turbine engine, comprising: a fan blade stage; and a bypass vane stage disposed proximate to the fan blade stage and operative to direct air to or from the fan blade stage, wherein the bypass vane stage includes: a plurality of composite vanes, each vane being defined by the same dimensions; and a plurality of composite vane platform segments having a combined plurality of openings, wherein each vane platform segment includes at least one of the openings; wherein each opening is configured to receive a portion of one of the vanes and to position the one of the vanes within the bypass vane stage; wherein the plurality of vane platform segments are configured to jointly form a ring to form at least part of the bypass vane stage in conjunction with the vanes positioned by the openings; and wherein at least some of the openings vary in position relative to others of the openings. 
         [0039]    In a refinement, each vane platform segment includes at least two of the openings. 
         [0040]    In another refinement, each vane platform segment includes at least three of the openings. 
         [0041]    In yet another refinement, each vane includes an extension configured to be received in one of the openings. 
         [0042]    In still another refinement, the extension includes a lip configured to retain the vane with one of the vane platform segments. 
         [0043]    In yet still another refinement, the extension has an airfoil shape, and wherein each opening has the same airfoil shape as the extension. 
         [0044]    Embodiments of the present invention include a method of manufacturing a bypass vane stage, comprising: molding a plurality of composite vanes, each vane being defined by the same dimensions; forming a plurality of composite vane platform segments configured to jointly form a ring; forming a plurality of openings in the plurality of composite vane platform segments, wherein each vane platform segment includes at least one opening; and wherein each opening is formed to receive a portion of one of the vanes and to position the one of the vanes within the bypass vane stage; and wherein at least some of the openings are formed to vary in position relative to others of the openings. 
         [0045]    In a refinement, the at least some of the openings are formed to vary in one or more of an axial direction, a circumferential direction and a setting angle direction relative to the others of the openings. 
         [0046]    In another refinement, the method further comprises forming an extension in each vane configured to be received in one of the openings. 
         [0047]    In yet another refinement, the method further comprises forming a lip on the extension, wherein the lip is configured to retain the vane with one of the vane platform segments. 
         [0048]    In still another refinement, the method further comprises: inserting one of the vanes into one of the openings; fastening the vane to one of the vane platform segments using a paste adhesive; and fastening a strap to the vane platform segment and an extension of the vane using the paste adhesive. 
         [0049]    While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment(s), but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as permitted under the law. Furthermore it should be understood that while the use of the word preferable, preferably, or preferred in the description above indicates that feature so described may be more desirable, it nonetheless may not be necessary and any embodiment lacking the same may be contemplated as within the scope of the invention, that scope being defined by the claims that follow. In reading the claims it is intended that when words such as “a,” “an,” “at least one” and “at least a portion” are used, there is no intention to limit the claim to only one item unless specifically stated to the contrary in the claim. Further, when the language “at least a portion” and/or “a portion” is used the item may include a portion and/or the entire item unless specifically stated to the contrary.