Patent Description:
Various types and configurations of vanes, such as structural guide vanes for a gas turbine engine, are known in the art. While these known vanes have various benefits, there is still room in the art for improvement. For example, there is a need in the art for a light weight structural guide vane which is relatively simple to manufacture.

<CIT> discloses subject matter according to the preamble of claim <NUM>.

According to an aspect of the present invention, a vane is provided for a gas turbine engine as claimed in claim <NUM>.

Various embodiments of the present invention are defined in the dependent claims, including any one or more of the individual features disclosed therein, alone or in any combination thereof.

<FIG> and <FIG> illustrate a multi-material vane <NUM> (e.g., a metal-composite vane) for a gas turbine engine. This vane <NUM> may be configured as a structural guide vane; e.g., a structural exit guide vane. For example, referring to <FIG>, the vane <NUM> may extend between and be structurally tied to an inner structure <NUM> of the gas turbine engine and an outer structure <NUM> of the gas turbine engine. With such a configuration, the vane <NUM> is configured to transfer loads between the inner structure <NUM> and the outer structure <NUM>. The vane <NUM> may also or alternatively be configured to direct flow within a flowpath <NUM> (e.g., a bypass flowpath) of the gas turbine engine. The vane <NUM> of the present disclosure, however, is not limited to such an exemplary vane configuration or arrangement within the gas turbine engine.

Referring to <FIG>, the vane <NUM> includes a vane airfoil <NUM>, a vane inner platform <NUM> (e.g., a shroud segment) and a vane outer platform <NUM> (e.g., a shroud segment). The vane <NUM> of <FIG> also include a vane inner mount <NUM> and a vane outer mount <NUM>. Of course, it is contemplated the vane <NUM> may alternatively be configured without one or more of the vane elements <NUM>-<NUM> and/or include one or more additional elements. For example, in some embodiments, the inner platform <NUM> and/or the outer platform <NUM> may be configured discrete from the vane <NUM>.

The vane airfoil <NUM> of <FIG> extends spanwise along a span line <NUM> between an airfoil inner end <NUM> and an airfoil outer end <NUM>, where the airfoil outer end <NUM> is positioned radially outboard of the airfoil inner end <NUM>. The vane airfoil <NUM> extends longitudinally along a camber line <NUM> between an (e.g., forward, upstream) airfoil leading edge <NUM> and an (e.g., aft, downstream) airfoil trailing edge <NUM>. Referring to <FIG>, the vane airfoil <NUM> extends laterally (e.g., widthwise) between an (e.g., pressure, concave) airfoil first side <NUM> and an (e.g., suction, convex) airfoil second side <NUM>. Referring to <FIG> and <FIG>, each of these vane airfoil elements <NUM>, <NUM>, <NUM> and <NUM> extends between and to the airfoil inner end <NUM> and the airfoil outer end <NUM>.

Referring to <FIG>, the vane airfoil <NUM> has an airfoil inner end portion <NUM>, an airfoil outer end portion <NUM> and an airfoil intermediate portion <NUM>. Each of these portions <NUM>-<NUM> defines a respective part of the airfoil elements <NUM>, <NUM>, <NUM> and <NUM>; see also <FIG>. The intermediate portion <NUM> extends spanwise between and to the inner end portion <NUM> and the outer end portion <NUM>. The inner end portion <NUM> is arranged at the airfoil inner end <NUM>, and is connected to the vane inner platform <NUM>. The outer end portion <NUM> is arranged at the airfoil outer end <NUM>, and is connected to the vane outer platform <NUM>.

Referring to <FIG>, the vane inner platform <NUM> is configured to form an inner peripheral portion of the flowpath <NUM>. The vane outer platform <NUM> is positioned radially outboard of the vane inner platform <NUM>. The vane outer platform <NUM> is configured to form an outer peripheral portion of the flowpath <NUM>.

The vane inner mount <NUM> is configured to attach and structurally tie the vane <NUM> to the inner structure <NUM>. The vane outer mount <NUM> is configured to attach and structurally tie the vane <NUM> to the outer structure <NUM>. Referring to <FIG>, the vane inner mount <NUM> is positioned radially inboard of and connected to the vane inner platform <NUM>. The vane outer mount <NUM> is position radially outboard of and connected to the vane outer platform <NUM>.

The vane airfoil <NUM> of <FIG> and <FIG> is configured as a multi-material (e.g., bimaterial) airfoil; e.g., a metallic-composite hybrid airfoil. The vane airfoil <NUM> of <FIG> and <FIG>, for example, includes an airfoil base section <NUM>, an airfoil first side section <NUM> and an airfoil second side section <NUM>. The base section <NUM> may be constructed from or otherwise base section material. An example of the base section material is metal such as, but not limited to, steel, titanium (Ti), aluminum (Al), nickel (Ni) or alloys thereof. The first side section <NUM> may be constructed from or otherwise include first side section non-metal material. The second side section <NUM> may be constructed from or otherwise include second side section non-metal material, which second side section non-metal material may be the same or different than the first side section non-metal material. Examples of the first and the second side section non-metal materials include, but are not limited to, composite materials (e.g., materials including fiber-reinforcement within a polymer matrix, such as carbon fiber and/or fiberglass within a thermoset or thermoplastic matrix).

Referring to <FIG>, the base section <NUM> of the vane airfoil <NUM> may be configured integrally with one or more or each of the other vane components <NUM>-<NUM>. The vane components <NUM> and <NUM>-<NUM> of <FIG>, for example, are configured together as a monolithic metal body. The vane components <NUM> and <NUM>-<NUM>, for example, may be cast, machined, additively manufactured or otherwise formed as a single body of material. The present disclosure, however, is not limited to such an exemplary monolithic metal body embodiment.

Referring to <FIG>, the base section <NUM> may have an I-beam configuration; e.g., an I-beam cross-sectional geometry when viewed, for example, in a plane perpendicular to the span line <NUM>. The base section <NUM> of <FIG> and <FIG>, for example, includes a leading edge segment <NUM>, a trailing edge segment <NUM> and an intermediate segment <NUM> where the edge segments <NUM> and <NUM> represent flange portions of the I-beam configuration and the intermediate segment <NUM> represents a web portion of the I-beam configuration. The base section <NUM> of <FIG> also includes an inner end segment <NUM> and an outer end segment <NUM> which cap ends of the intermediate segment <NUM>.

The leading edge segment <NUM> extends along and at least partially (e.g., completely) defines the airfoil leading edge <NUM>. The leading edge segment <NUM> also partially defines a (e.g., forward, upstream) first portion of the airfoil first side <NUM> and/or a (e.g., forward, upstream) first portion of the airfoil second side <NUM>, where the first portions meet at the airfoil leading edge <NUM> and extend longitudinally towards the airfoil trailing edge <NUM> as well as extend spanwise between the airfoil ends <NUM> and <NUM>.

The trailing edge segment <NUM> extends along and at least partially (e.g., completely) defines the airfoil trailing edge <NUM>. The trailing edge segment <NUM> also partially defines a (e.g., aft, downstream) second portion of the airfoil first side <NUM> and/or a (e.g., aft, downstream) second portion of the airfoil second side <NUM>, where the second portions meet at the airfoil trailing edge <NUM> and extend longitudinally towards the airfoil leading edge <NUM> as well as extend spanwise between the airfoil ends <NUM> and <NUM>.

The intermediate segment <NUM> extends longitudinally between and is connected to the leading edge segment <NUM> and the trailing edge segment <NUM>. The intermediate segment <NUM> extends spanwise between and is connected to the inner end segment <NUM> and the outer end segment <NUM>.

Referring to <FIG>, at an interface between the leading edge segment <NUM> and the intermediate segment <NUM>, the leading edge segment <NUM> has a lateral width <NUM> that is greater than a lateral width <NUM> of the intermediate segment <NUM>. At an interface between the trailing edge segment <NUM> and the intermediate segment <NUM>, the trailing edge segment <NUM> has a lateral width <NUM> that is greater than the lateral width <NUM> of the intermediate segment <NUM>. Similarly, referring to <FIG>, at an interface between the inner end segment <NUM> and the intermediate segment <NUM>, the inner end segment <NUM> has a lateral width <NUM> that is greater than the lateral width <NUM> of the intermediate segment <NUM>. At an interface between the outer end segment <NUM> and the intermediate segment <NUM>, the outer end segment <NUM> has a lateral width <NUM> that is greater than the lateral width <NUM> of the intermediate segment <NUM>.

With the foregoing configuration, the base section <NUM> is configured with one or more pockets <NUM> and <NUM>; e.g., recesses. The first pocket <NUM> is disposed at the airfoil first side <NUM> (see <FIG>) and projects partially into the base section <NUM> to the intermediate segment <NUM>. The second pocket <NUM> is disposed at the airfoil second side <NUM> (see <FIG>) and projects partially into the base section <NUM> to the intermediate segment <NUM>. The intermediate segment <NUM>, however, (e.g., completely) laterally separates the first pocket <NUM> form the second pocket <NUM>. The intermediate segment <NUM> of <FIG> and, more particularly, the entire base section <NUM>, for example, is configured as an aperture free body. The first pocket <NUM> and the second pocket <NUM> may thereby be (e.g., completely) discrete from one another.

The intermediate segment <NUM> of <FIG> includes an inner portion <NUM>, an outer portion <NUM> and an intermediate portion <NUM>. These portions <NUM>-<NUM> are longitudinally aligned along the camber line <NUM>. The intermediation portion <NUM> extends spanwise between and to the inner portion <NUM> and the outer portion <NUM>. Referring to <FIG>, the inner portion <NUM> provides a lateral width transition between the inner end segment <NUM> and the intermediation portion <NUM> of the intermediate segment <NUM>. Similarly, the outer portion <NUM> provides a lateral width transition between the outer end segment <NUM> and the intermediation portion <NUM> of the intermediate segment <NUM>. For example, referring to <FIG>, one or each portion <NUM>, <NUM> may be configured to provide a stepped transition where a lateral width of the portion <NUM>, <NUM> is less than a lateral width of the end segment <NUM>, <NUM> and greater than a lateral width of the intermediation portion <NUM>. Referring to <FIG>, one or each portion <NUM>, <NUM> may alternatively be configured as a tapered transition where a lateral width of the portion <NUM>, <NUM> (e.g., smoothly, continuously and/or otherwise) tapers down from the lateral width of the end segment <NUM>, <NUM> to the lateral width of the intermediation portion <NUM>. The present disclosure, however, is not limited to including such transitions.

Referring to <FIG> and <FIG>, the first side section <NUM> is seated within the first pocket <NUM> and connected (e.g., bonded and/or otherwise attached) to the base section <NUM> and its intermediate segment <NUM>. The first side section <NUM> extends longitudinally between and longitudinally abuts the leading edge segment <NUM> and the trailing edge segment <NUM>. The first side section <NUM> extends spanwise between and spanwise abuts the inner end segment <NUM> and the outer end segment <NUM>. The first side section <NUM> along with the base section segments <NUM>, <NUM>, <NUM> and <NUM> are configured to collectively form the airfoil first side <NUM> and an exterior flow surface of the airfoil <NUM> at that first side <NUM>. Thus, the base section <NUM> and the first side section <NUM> collectively form the intermediation portion <NUM> of the airfoil <NUM> at its first side <NUM>. However, the base section <NUM> alone may form one or both of the end portions <NUM>, <NUM> of the airfoil <NUM> at its first side <NUM>.

The second side section <NUM> is seated within the second pocket <NUM> and connected (e.g., bonded and/or otherwise attached) to the base section <NUM>. The second side section <NUM> extends longitudinally between and longitudinally abuts the leading edge segment <NUM> and the trailing edge segment <NUM>. The second side section <NUM> extends spanwise between and spanwise abuts the inner end segment <NUM> and the outer end segment <NUM>. The second side section <NUM> along with the base section segments <NUM>, <NUM>, <NUM> and <NUM> are configured to collectively form the airfoil second side <NUM> and an exterior flow surface of the airfoil <NUM> at that second side <NUM>. Thus, the base section <NUM> and the second side section <NUM> collectively form the intermediation portion <NUM> of the airfoil <NUM> at its second side <NUM>. However, the base section <NUM> alone may form one or both of the end portions <NUM>, <NUM> of the airfoil <NUM> at its second side <NUM>.

Referring to <FIG>, since the intermediate segment <NUM> is aperture free (e.g., solid), the base section <NUM> and its intermediate segment <NUM> (e.g., completely) separate the first side section <NUM> from the second side section <NUM>. This separation may facilitate a relatively low complexity manufacturing process. For example, the first pocket <NUM> may first be (e.g., completely) filled with the first non-metal material to form the first side section <NUM>. The body may then be flipped over and the second pocket <NUM> may then be (e.g., completely) filled with the second non-metal material to form the second side section <NUM>, or vice versa. The present disclosure, however, is not limited to any particular manufacturing techniques or steps.

Referring to <FIG>, each side section <NUM>, <NUM> has an end-to-end length <NUM> along the span line <NUM>. Each airfoil <NUM> has an end-to-end length <NUM> (e.g., vane height) along the span line <NUM>. The side section length <NUM> may be less than the airfoil length <NUM> due to, for example, provision of the end portions <NUM> and <NUM>.

<FIG> is a side cutaway illustration of a geared turbine engine <NUM> which may be configured with one or more (e.g., a circumferential array) of the vanes <NUM>. This turbine engine <NUM> extends along an axial centerline <NUM> between an upstream airflow inlet <NUM> and a downstream airflow exhaust <NUM>. The turbine engine <NUM> includes a fan section <NUM>, a compressor section <NUM>, a combustor section <NUM> and a turbine section <NUM>. The compressor section <NUM> includes a low pressure compressor (LPC) section 99A and a high pressure compressor (HPC) section 99B. The turbine section <NUM> includes a high pressure turbine (HPT) section 101A and a low pressure turbine (LPT) section 101B.

The engine sections <NUM>-101B are arranged sequentially along the centerline <NUM> within an engine housing <NUM>. This housing <NUM> includes an inner case <NUM> (e.g., a core case) and an outer case <NUM> (e.g., a fan case). The inner case <NUM> may house one or more of the engine sections 99A-101B; e.g., an engine core. The inner case <NUM> is configured with, includes or is part of the inner structure <NUM>. The outer case <NUM> may house at least the fan section <NUM>. The outer case <NUM> is configured with, includes or is part of the outer structure <NUM>.

Each of the engine sections <NUM>, 99A, 99B, 101A and 101B includes a respective rotor <NUM>-<NUM>. Each of these rotors <NUM>-<NUM> includes a plurality of rotor blades arranged circumferentially around and connected to one or more respective rotor disks. The rotor blades, for example, may be formed integral with or mechanically fastened, welded, brazed, adhered and/or otherwise attached to the respective rotor disk(s).

The fan rotor <NUM> is connected to a gear train <NUM>, for example, through a fan shaft <NUM>. The gear train <NUM> and the LPC rotor <NUM> are connected to and driven by the LPT rotor <NUM> through a low speed shaft <NUM>. The HPC rotor <NUM> is connected to and driven by the HPT rotor <NUM> through a high speed shaft <NUM>. The shafts <NUM>-<NUM> are rotatably supported by a plurality of bearings <NUM>; e.g., rolling element and/or thrust bearings. Each of these bearings <NUM> is connected to the engine housing <NUM> by at least one stationary structure such as, for example, an annular support strut.

During operation, air enters the turbine engine <NUM> through the airflow inlet <NUM>. This air is directed through the fan section <NUM> and into a core flowpath <NUM> and a bypass flowpath (e.g., the flowpath <NUM> of <FIG>). The core flowpath <NUM> extends sequentially through the engine sections 99A-101B. The air within the core flowpath <NUM> may be referred to as "core air". The bypass flowpath <NUM> extends through a bypass duct, which bypasses the engine core. The air within the bypass flowpath <NUM> may be referred to as "bypass air".

The rotation of the turbine rotor <NUM> also drives rotation of the fan rotor <NUM>, which propels bypass air through and out of the bypass flowpath <NUM>.

The vane <NUM> / an assembly including the vane <NUM> may be included in various turbine engines other than the one described above. The vane <NUM>, for example, may be included in a geared turbine engine where a gear train connects one or more shafts to one or more rotors in a fan section, a compressor section and/or any other engine section. Alternatively, the vane <NUM> may be included in a turbine engine configured without a gear train. The vane <NUM> may be included in a geared or non-geared turbine engine configured with a single spool, with two spools (e.g., see <FIG>), or with more than two spools. The turbine engine may be configured as a turbofan engine, a turbojet engine, a propfan engine, a pusher fan engine or any other type of turbine engine. The present disclosure therefore is not limited to any particular types or configurations of turbine engines.

Claim 1:
A vane (<NUM>) for a gas turbine engine, comprising:
an airfoil (<NUM>) extending along a camber line (<NUM>) between a leading edge (<NUM>) and a trailing edge (<NUM>), the airfoil (<NUM>) extending along a span line (<NUM>) between an inner end (<NUM>) and an outer end (<NUM>), the airfoil (<NUM>) extending laterally between a first side (<NUM>) and a second side (<NUM>), and the airfoil (<NUM>) including a base section (<NUM>), a first side section (<NUM>) and a second side section (<NUM>);
the base section (<NUM>) defining at least a portion of the trailing edge (<NUM>) of the airfoil (<NUM>), the base section (<NUM>) laterally between and connected to the first side section (<NUM>) and the second side section (<NUM>), and the base section (<NUM>) comprising metal material;
the first side section (<NUM>) defining at least a portion of the first side (<NUM>) of the airfoil (<NUM>), and the first side section (<NUM>) comprising first non-metal material; and
the second side section (<NUM>) defining at least a portion of the second side (<NUM>) of the airfoil (<NUM>), and the second side section (<NUM>) comprising second non-metal material,
characterized in that
the base section (<NUM>) has a first portion and a second portion aligned along the camber line (<NUM>);
the first portion is between the second portion and one of the inner end (<NUM>) and the outer end (<NUM>) along the span line (<NUM>); and
the first portion has a first lateral thickness,
characterised in that:
the second portion has a second lateral thickness that is less than the first lateral thickness; and
at least one of the first side section (<NUM>) or the second side section (<NUM>) overlaps and is connected to the first portion and the second portion.