Patent Publication Number: US-11643937-B2

Title: System for an improved stator assembly

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a divisional of, and claims priority to, and the benefit of Non-Provisional application Ser. No. 16/667,501, filed Oct. 29, 2019 for SYSTEM FOR AN IMPROVED STATOR ASSEMBLY, which is incorporated in its entirety by reference herein for all purposes. 
    
    
     FIELD 
     The present disclosure relates to gas turbine engines, and more specifically, to a system for an improved stator assembly. 
     BACKGROUND 
     Gas turbine engines typically include a compressor section to pressurize inflowing air, a combustor section to burn a fuel in the presence of the pressurized air, and a turbine section to extract energy from the resulting combustion gases. The compressor section typically may comprise alternating rows of rotors and stators, ending with an exit guide vane. The exit guide vane may be angled to remove swirl from the inflowing air, before directing air into a diffuser assembly. 
     SUMMARY 
     A stator assembly is disclosed herein. The stator assembly may comprise: a vane; a ring having a slot configured to receive the vane; a potting component disposed between the vane and the ring, the potting component configured to join the vane and the ring; and a potting embedded component disposed within the potting component, the potting embedded component configured to reduce internal tension in the potting component. 
     In various embodiments, the potting embedded component is at least one of a woven structure or a chain-link structure. A first end of the potting embedded component may be tangent to a non-gas path surface of the ring, and wherein a second end of the potting embedded component is tangent to a pressure side of the vane. The potting embedded component may comprise a sheet. The potting embedded component may be disposed around a perimeter of the vane. The potting embedded component may comprise a serpentine shape. The potting embedded component may contact a portion of the vane and a portion of a wall of the slot. The potting embedded component may be non-metallic. 
     A stator assembly is disclosed herein. The stator assembly may comprise: a vane comprising a suction side and a pressure side; a ring having a slot configured to receive the vane; a potting component disposed between the vane and the ring, the potting component configured to join the vane and the ring; a first potting embedded component disposed on the suction side of the vane, the first potting embedded component disposed within the potting component; and a second potting embedded component disposed on the pressure side of the vane, the second potting embedded component disposed within the potting component. 
     In various embodiments, the first potting embedded component may comprise a first flange and a second flange disposed radially outward from the first flange, the second flange defining a groove, and wherein the groove receives a wall defined by the slot of the ring. The first potting embedded component may comprise a plurality of fingers, each finger in the plurality of fingers extending from the second flange toward the vane and radially away from the second flange. Each finger in the plurality of fingers may include a convex surface opposite the vane. The first potting embedded component and the second potting embedded component may be deformable. The first potting embedded component and the second potting embedded component may be configured to receive the vane during assembly of the stator assembly. 
     A gas-turbine engine is disclosed herein. The gas-turbine engine may comprise: a stator assembly, comprising: an inner diameter (ID) ring; an outer diameter (OD) ring disposed radially outward from the ID ring; a vane disposed between the ID ring and the OD ring; a slot disposed in at least one of the ID ring or the OD ring; a potting component disposed in the slot, the potting component coupling the vane to the slot; and a first potting embedded component disposed within the potting component, the first potting embedded component comprising a non-metallic material. 
     In various embodiments, the first potting embedded component may be at least one of a woven structure or a chain-link structure. The first potting embedded component may comprise a sheet disposed around a perimeter of the vane in the slot. The first potting embedded component may comprise a serpentine shape, and wherein the first potting component contacts a portion of the vane and a portion of a wall of the slot. The first potting embedded component may be disposed on a pressure side of the vane. The stator assembly may further comprise a second potting embedded component disposed on a suction side of the vane. 
     The forgoing features and elements may be combined in various combinations without exclusivity, unless expressly indicated herein otherwise. These features and elements as well as the operation of the disclosed embodiments will become more apparent in light of the following description and accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The subject matter of the present disclosure is particularly pointed out and distinctly claimed in the concluding portion of the specification. A more complete understanding of the present disclosure, however, may best be obtained by referring to the detailed description and claims when considered in connection with the following illustrative figures. In the following figures, like reference numbers refer to similar elements and steps throughout the figures. 
         FIG.  1    illustrates a gas turbine engine, in accordance with various embodiments; 
         FIG.  2    illustrates a low pressure compressor section of a gas turbine engine, in accordance with various embodiments; 
         FIG.  3    illustrates a top view of an inner diameter (ID) ring of a stator assembly, in accordance with various embodiments; 
         FIG.  4    illustrates a perspective view of a portion of a stator assembly, in accordance with various embodiments; 
         FIG.  5    illustrates a cross-sectional view of a portion of a stator assembly, in accordance with various embodiments; 
         FIG.  6 A  illustrates a potting embedded component of a stator assembly, in accordance with various embodiments; 
         FIG.  6 B  illustrates a potting embedded component of a stator assembly, in accordance with various embodiments; 
         FIG.  7    illustrates a perspective view of a portion of a stator assembly, in accordance with various embodiments; 
         FIG.  8    illustrates a cross-sectional view of a portion of a stator assembly, in accordance with various embodiments; 
         FIG.  9    illustrates a perspective view of a portion of a stator assembly, in accordance with various embodiments; 
         FIG.  10    illustrates a cross-sectional view of a portion of a stator assembly, in accordance with various embodiments; 
     
    
    
     Elements and steps in the figures are illustrated for simplicity and clarity and have not necessarily been rendered according to any particular sequence. For example, steps that may be performed concurrently or in different order are illustrated in the figures to help to improve understanding of embodiments of the present disclosure. 
     DETAILED DESCRIPTION 
     The detailed description of exemplary embodiments herein makes reference to the accompanying drawings, which show exemplary embodiments by way of illustration. While these exemplary embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosures, it should be understood that other embodiments may be realized and that logical changes and adaptations in design and construction may be made in accordance with this disclosure and the teachings herein. Thus, the detailed description herein is presented for purposes of illustration only and not of limitation. 
     The scope of the disclosure is defined by the appended claims and their legal equivalents rather than by merely the examples described. For example, the steps recited in any of the method or process descriptions may be executed in any order and are not necessarily limited to the order presented. Furthermore, any reference to singular includes plural embodiments, and any reference to more than one component or step may include a singular embodiment or step. Also, any reference to attached, fixed, coupled, connected or the like may include permanent, removable, temporary, partial, full and/or any other possible attachment option. Additionally, any reference to without contact (or similar phrases) may also include reduced contact or minimal contact. Surface shading lines may be used throughout the figures to denote different parts but not necessarily to denote the same or different materials. 
     As used herein, “aft” refers to the direction associated with the tail (e.g., the back end) of an aircraft, or generally, to the direction of exhaust of the gas turbine engine. As used herein, “forward” refers to the direction associated with the nose (e.g., the front end) of an aircraft, or generally, to the direction of flight or motion. 
     In various embodiments, and with reference to  FIG.  1   , a gas turbine engine  120  is disclosed. Gas turbine engine  120  may comprise a two-spool turbofan that generally incorporates a fan section  122 , a compressor section  124 , a combustor section  126 , and a turbine section  128 . Gas turbine engine  120  may also comprise, for example, an augmenter section, and/or any other suitable system, section, or feature. In operation, fan section  122  may drive air along a bypass flow-path B, while compressor section  124  may further drive air along a core flow-path C for compression and communication into combustor section  126 , before expansion through turbine section  128 .  FIG.  1    provides a general understanding of the sections in a gas turbine engine, and is not intended to limit the disclosure. The present disclosure may extend to all types of applications and to all types of turbine engines, including, for example, such as turbojets, turboshafts, and three spool (plus fan) turbofans wherein an intermediate spool includes an intermediate pressure compressor (“LPC”) between a Low Pressure Compressor (“LPC”) and a High Pressure Compressor (“HPC”), and an Intermediate Pressure Turbine (“IPT”) between the High Pressure Turbine (“HPT”) and the Low Pressure Turbine (“LPT”). 
     In various embodiments, gas turbine engine  120  may comprise a low speed spool  130  and a high speed spool  132  mounted for rotation about an engine central longitudinal axis A-A′ relative to an engine static structure  136  via one or more bearing systems  138  (shown as, for example, bearing system  138 - 1  and bearing system  138 - 2  in  FIG.  1   ). It should be understood that various bearing systems  138  at various locations may alternatively or additionally be provided, including, for example, bearing system  138 , bearing system  138 - 1 , and/or bearing system  138 - 2 . 
     In various embodiments, low speed spool  130  may comprise an inner shaft  140  that interconnects a fan  142 , a low pressure (or first) compressor section (“LPC”)  144 , and a low pressure (or first) turbine section  146 . Inner shaft  140  may be connected to fan  142  through a geared architecture  148  that can drive fan  142  at a lower speed than low speed spool  130 . Geared architecture  148  may comprise a gear assembly  160  enclosed within a gear housing  162 . Gear assembly  160  may couple inner shaft  140  to a rotating fan structure. High speed spool  132  may comprise an outer shaft  150  that interconnects a high pressure compressor (“HPC”)  152  (e.g., a second compressor section) and high pressure (or second) turbine section  154 . A combustor  156  may be located between HPC  152  and high pressure turbine  154 . A mid-turbine frame  157  of engine static structure  136  may be located generally between high pressure turbine  154  and low pressure turbine  146 . Mid-turbine frame  157  may support one or more bearing systems  138  in turbine section  128 . Inner shaft  140  and outer shaft  150  may be concentric and may rotate via bearing systems  138  about engine central longitudinal axis A-A′. As used herein, a “high pressure” compressor and/or turbine may experience a higher pressure than a corresponding “low pressure” compressor and/or turbine. 
     In various embodiments, the air along core airflow C may be compressed by LPC  144  and HPC  152 , mixed and burned with fuel in combustor  156 , and expanded over high pressure turbine  154  and low pressure turbine  146 . Mid-turbine frame  157  may comprise airfoils  159  located in core airflow path C. Low pressure turbine  146  and high pressure turbine  154  may rotationally drive low speed spool  130  and high speed spool  132 , respectively, in response to the expansion. 
     In various embodiments, and with reference to  FIG.  2   , LPC  144  of  FIG.  1    is depicted in greater detail. Inflowing air may proceed through LPC  144  and into a stator assembly  200 . The inflowing air may travel through a stator assembly  200 , configured to define an air flow path from the rotating LPC  144  module to HPC  152  (from  FIG.  1   ). In various embodiments, stator assembly  200  may be mounted adjacent to HPC  152  (from  FIG.  1   ), in gas turbine engine  120 . Stator assembly  200  may comprise a full ring stator assembly, wherein a plurality of stator assemblies  200  may be located circumferentially around the defined airflow path. 
     In various embodiments, stator assembly  200  may increase pressure in LPC  144 , and straighten and direct air flow. Stator assembly  200  may comprise an inner diameter (ID) ring  217  radially spaced apart from an outer diameter (OD) ring  218 . In various embodiments, OD ring  218  may form a portion of an outer core engine structure, and ID ring  217  may form a portion of an inner core engine structure to at least partially define an annular core gas flow. In various embodiments, stator assembly  200  may be configured to couple to the inside of gas turbine engine  120  using any suitable method known in the art, such as, for example, via OD ring  218  and ID ring  217 . For example, OD ring  218  and ID ring  217  may each comprise a tab located on a radially outward surface (from engine central longitudinal axis A-A′), configured to couple with a slot in the inside of gas turbine engine  120 . In various embodiments, an exit guide vane  210  may be coupled at a first end to OD ring  218  and coupled at a second end to ID ring  217 . Exit guide vane  210  may be configured to reduce airflow swirl and direct airflow into HPC  152  (from  FIG.  1   ). 
     Referring now to  FIG.  3   , a top view of a portion of an ID ring  217 , in accordance with various embodiments, is illustrated. The ID ring  217  may comprise a slot  310  disposed in a radially outer surface  312  of ID ring  217 . The slot  310  may be configured to receive a respective exit guide vane  210  from  FIG.  2   . Similarly, OD ring  218  may comprise a corresponding slot on a radially inner surface opposite the slot  310  of the ID ring  217 . The slot of the OD ring  218  may be configured to receive a radially outer end of the respective exit guide vane  210 . 
     Referring now to  FIG.  4   , a portion of a stator assembly  400 , in accordance with various embodiments, is illustrated. The stator assembly  400  comprises vane  410  (e.g., exit guide vane  210 ), a ring  420  (e.g., ID ring  217  or OD ring  218 ), a potting component  430  (e.g., a liquid sealant that cures to a solid state and joins a first component to a second component), and a potting embedded component  440 . The vane  410  comprises a root  412 , a pressure side  414  and a suction side  416 . The root  412  may be disposed within the potting component  430 . In various embodiments, vane  410  may be made from any type of metal known in the art. For example, vane  410  may comprise an aluminum alloy, titanium alloy, or the like. ring  420  comprises a non-gas path surface  422 . A “gas path surface” as defined herein is a surface exposed to the core flow path C (from  FIG.  1   ) during normal operation of the gas-turbine. As such, a “non-gas path surface” as defined herein, is a surface that is not exposed to the core flow path C (from  FIG.  1   ) during normal operation of the gas-turbine engine. Similar to vane  410 , ring  420  may comprise any type of metal known in the art, such as an aluminum alloy, titanium alloy, or the like. 
     In various embodiments, the vane  410  is coupled to the ring  420  by the potting component  430 . For example, a portion of the potting component  430  may be disposed in a slot of ring  420  and disposed between the ring  420  and the root  412  of vane  410 . During assembly, a first layer of the potting component  430  may be in liquid form and completely fill slot  424  of ring  420 . Next, a potting embedded component  440  may be disposed on the first layer of the potting component  430  proximate the pressure side  414  of vane  410 . Then, a second layer of the potting component  430  may be disposed on the embedded potting component, which may sandwich the potting embedded component  440  between the first layer and the second layer of the potting component  430 . The potting component  430  may then be cured and join the root  412  of vane  410  to ring  420 . The potting component  430  may be a thermoplastic elastomer, silicone, silicone rubber, natural rubber, or the like. In various embodiments, the potting component  430  is made of silicone rubber. 
     Referring now to  FIG.  5   , a cross-sectional view of stator assembly  400  from  FIG.  4    along section line A-A, in accordance with various embodiments, is illustrated. The ring  420  may further comprise a slot  424  disposed through ring  420  extending from the non-gas path surface  422  to a gas-path surface  426 . In various embodiments, root  412  of vane  410  is disposed in slot  424  of ring  420 . In various embodiments, a first layer  432  of potting component  430  may be disposed in slot  424  of ring  420  between the slot  424  and the root  412 . This may ensure that the vane  410  and the ring  420  are not in direct contact. Next, a second layer  433  of the potting component  430  may be disposed on pressure side  414  of vane  410  proximate the non-gas path surface  422  of ring  420 . The second layer  433  may have a first end that is tangent to a surface of pressure side  414  and a second end that is tangent to non-gas path surface  422 . In various embodiments, the potting embedded component  440  is disposed on the second layer of the potting component  430 . Similar to the second layer  433  of the potting component  430 , potting embedded component  440  may have a first end that is tangent to a surface of pressure side  414  and a second end that is tangent to non-gas path surface  422 . A third layer  434  of potting component  430  may be disposed on the second layer  433  and first layer  432  of the potting component and extend around a perimeter of vane  410  (as shown in  FIG.  4   ) and further couple root  412  of vane  410  to non-gas path surface  422 . As such, potting embedded component  440  may be completely embedded in potting component  430 . 
     In various embodiments, and with reference to  FIGS.  4 ,  5 ,  6 A, and  6 B , the potting embedded component  440  may be any suitable structure. For example, potting embedded component  440  may be woven and/or braided (e.g., potting embedded component  440 A) and/or a chain-link structure (e.g., potting embedded component  440 B). In various embodiments, potting embedded component  440  may also be any suitable material to reduce internal tension of the potting component  430  during operation of the gas-turbine engine. For example, potting embedded component  440  may be metallic or non-metallic. In various embodiments, potting embedded component is made of plastic, or the like. Plastic may reduce cost of the assembly and/or strengthen the bond of the potting component during operation. In various embodiments, the potting embedded component  440  may be shaped to maximize a surface area of the potting embedded component  440  disposed in the rubber (e.g., the first end of the potting embedded component  440  is tangent to the pressure side surface and the second end of the potting embedded component  440  is tangent to the radially outer surface  422  of the ID ring  420 . 
     Referring now to  FIG.  7   , a portion of a stator assembly  700  prior to bonding of a potting component, in accordance with various embodiments, is illustrated. The stator assembly  700  comprises vane  710 , ring  720  (e.g., ID ring  217  or ID ring  218 ), and a potting embedded component  740 . The potting embedded component  740  may be disposed in a slot  724  of stator assembly  700 . In various embodiments, the potting embedded component  740  may extend around a perimeter of vane  710 . The potting embedded component  740  may be in a serpentine shape and contact a portion of a vane outer surface  711  followed by a portion of a slot surface  725  disposed opposite the vane outer surface  711 . 
     Referring now to  FIG.  8   , a cross-section of stator assembly  700  from  FIG.  7    along section line B-B after bonding of a potting component, in accordance with various embodiments, is illustrated. After the potting embedded component  740  is disposed within slot  724  in accordance with  FIG.  7   , potting component  730  in liquid form may be disposed in slot  724  between potting embedded component  740 , slot  724 , and vane  710 . In various embodiments, potting embedded component  740  may contact a portion of a vane outer surface  711  proximate a root  712  of vane  710  and/or a portion of a wall of slot  724  that is opposite the vane outer surface  711 . In various embodiments, the potting embedded component  740  has a material stiffness that is greater than a material stiffness of the potting component  730 . As such, a load through the vane  710 , during operation of the gas turbine engine, may be absorbed by the potting embedded component  740  and/or decrease stress in the potting component  730 . As such, the potting embedded component  740  may prevent disbond of the potting component  730  during operation. 
     In various embodiments, potting embedded component  740  may be any suitable structure. For example, potting embedded component  740  may be a sheet, as illustrated in  FIGS.  7  and  8   , or the like. In various embodiments, potting embedded component  740  may also be any suitable material to prevent internal tension of the potting component  730  during operation of the gas-turbine engine. For example, potting embedded component  740  may be non-metallic to prevent metal to metal contact. In various embodiments, potting embedded component  740  is made of a thermoset or thermoplastic, or the like. Thermoplastic may reduce cost of the assembly and/or strengthen the bond of the potting component during operation. In various embodiments, the potting embedded component  740  may be shaped to maximize a surface area of the potting embedded component  740  disposed in the potting component  730  (e.g., the frequency of a serpentine pattern may be increased to provide greater surface area of the potting embedded component  740 ). 
     Referring now to  FIG.  9   , a portion of a stator assembly  900  prior to bonding of a potting component without a ring, in accordance with various embodiments, is illustrated. The stator assembly  900  comprises vane  910 , a first potting embedded component  940  and a second potting embedded component  950 . The first potting embedded component  940  may be disposed on a suction side  916  of the vane  910 . The second potting embedded component  950  may be disposed on a pressure side  914  of the vane  910 . 
     In various embodiments, the first potting embedded component  940  comprises a groove  942  disposed between a first flange  941  and a second flange  943 . The groove  942  may be configured to receive ring therebetween (as shown in  FIG.  10   ). In various embodiments, the first flange  441  contacts a gas-path surface of ring and the second flange  943  contact a non-gas path surface of ring  920 . The first potting embedded component  940  may further comprise a plurality of fingers  945  extending from the second flange  943  toward suction side  916  of the vane  910  and radially away from a gas-path surface of a ring. In various embodiments, first potting embedded component  940  is deformable. Each finger in the plurality of fingers  945  may include an outer surface having a convex shape. The convex shape of the outer fingers may guide a potting component during injection of the potting component in liquid form (i.e., the potting component in liquid form may be screed over the convex surface and fill gaps between adjacent fingers) and/or create an easier manufacturing process to create a fillet with the potting component. 
     In various embodiments, the second potting embedded component  950  may comprise the same features of the first potting component with respect to the pressure side  914  of vane  910 . During assembly, a root  912  of vane  910  may be disposed between the first potting embedded component  940  and the second potting embedded component  950  and into slot of a ring (e.g., ID ring  217  or OD ring  218 ). The plurality of fingers of each potting embedded component  940 ,  950  may deform and receive the root  912  of vane  910  and press the groove of each potting embedded component  940  against a respective wall of a respective slot. Next, a potting component in liquid form is injected into the slot, and along the plurality of fingers of each potting embedded component  950 . Then, the potting component is cured, fully embedding each potting embedded component  940 ,  950 . 
     Referring now to  FIG.  10   , a cross-section of stator assembly  900  from  FIG.  9    along section line C-C after bonding of a potting component to a ring  920  (e.g., ID ring  217  or OD ring  218 ), in accordance with various embodiments, is illustrated. After the potting embedded component  940  is disposed within slot  924  in accordance with  FIG.  9   , potting component  930  in liquid form may be disposed in slot  924  between potting embedded component  940 , non-gas path surface  922  of ring  920 , gas-path surface  926  of ring  920 , and vane  910 . In various embodiments, each finger in the plurality of fingers of each potting embedded component  940 ,  950  may contact a portion of the suction side  916  or the pressure side  914  proximate a root  912  of vane  910 . The groove in each potting embedded component  940 ,  950  may receive a wall of slot  924  that is opposite either the pressure side  914  or the suction side  916 . The groove of each potting embedded component  940 ,  950  may secure each potting embedded component  940 ,  950  to a respective wall of ring  920  within slot  924 . As such, the potting embedded components  940 ,  950  may prevent disbond of the potting component  930  during operation. 
     In various embodiments, each potting embedded component  940 ,  950  may be any suitable material to prevent internal tension of the potting component  930  during operation of the gas-turbine engine. For example, potting embedded component  940  may be non-metallic to prevent any metal to metal contact. In various embodiments, each potting embedded component  940 ,  950  is made of plastic, or the like. Plastic may reduce cost of the assembly and/or strengthen the bond of the potting component during operation. 
     Although described herein with respect to an ID ring of a stator assembly, an OD ring of a stator assembly in accordance with the ID ring described herein is within the scope of this disclosure. 
     Benefits, other advantages, and solutions to problems have been described herein with regard to specific embodiments. Furthermore, the connecting lines shown in the various figures contained herein are intended to represent exemplary functional relationships and/or physical couplings between the various elements. It should be noted that many alternative or additional functional relationships or physical connections may be present in a practical system. However, the benefits, advantages, solutions to problems, and any elements that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as critical, required, or essential features or elements of the disclosures. The scope of the disclosures is accordingly to be limited by nothing other than the appended claims and their legal equivalents, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.” Moreover, where a phrase similar to “at least one of A, B, or C” is used in the claims, it is intended that the phrase be interpreted to mean that A alone may be present in an embodiment, B alone may be present in an embodiment, C alone may be present in an embodiment, or that any combination of the elements A, B and C may be present in a single embodiment; for example, A and B, A and C, B and C, or A and B and C. 
     Systems, methods and apparatus are provided herein. In the detailed description herein, references to “various embodiments”, “one embodiment”, “an embodiment”, “an example embodiment”, etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described. After reading the description, it will be apparent to one skilled in the relevant art(s) how to implement the disclosure in alternative embodiments. Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 U.S.C. 112(f), unless the element is expressly recited using the phrase “means for.” As used herein, the terms “comprises”, “comprising”, or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.