Structural composite fan exit guide vane for a turbomachine

Abstract

A structural composite fan exit guide vane assembly uses single component monolithic structural guide vane segments to provide airflow correction and structural support in a gas turbine engine.

1 . A structural composite fan exit guide vane segment comprising:
 a monolithic component having an inner diameter shroud;   an outer diameter shroud; and   a plurality of fan exit guide vanes connecting said inner diameter shroud and said outer diameter shroud.   
     
     
         2 . The structural composite fan exit guide vane segment of  claim 1 , wherein said monolithic component is constructed of a composite material. 
     
     
         3 . The structural composite fan exit guide vane segment of  claim 2 , wherein said composite material comprises a carbon/epoxy laminate molding. 
     
     
         4 . The structural composite fan exit guide vane segment of  claim 1 , wherein said inner diameter shroud comprises at least one counter sunk hole operable to connect said inner diameter shroud to an engine frame. 
     
     
         5 . The structural composite fan exit guide vane segment of  claim 1 , wherein said outer diameter shroud comprises at least one counter sunk hole operable to connect said outer diameter shroud to an engine casing. 
     
     
         6 . The structural composite fan exit guide vane segment of  claim 1 , further comprising an integral flow path spacer affixed to a single side of said outer diameter shroud. 
     
     
         7 . The structural composite fan exit guide vane segment of  claim 1 , wherein each of said fan exit guide vanes has an airfoil shaped profile. 
     
     
         8 . The structural composite fan exit guide vane segment of  claim 1 , wherein said plurality of fan exit guide vanes comprises exactly two fan exit guide vanes. 
     
     
         9 . The structural composite fan exit guide vane segment of  claim 1 , wherein said plurality of fan exit guide vanes comprise a fiber reinforced polymer matrix composite. 
     
     
         10 . The structural composite fan exit guide vane segment of  claim 1 , wherein said inner diameter shroud is an arc segment having a first radius, said outer diameter shroud is an arc segment having an second radius, and said second radius is larger than said first radius. 
     
     
         11 . A gas turbine engine comprising;
 a fan; and   a fan frame supporting said fan comprising a plurality of fan exit guide vane segments, each of said fan exit guide vane segments having a single monolithic component having an inner diameter shroud, an outer diameter shroud, and a plurality of fan exit guide vanes connecting said inner diameter shroud and said outer diameter shroud.   
     
     
         12 . The gas turbine engine of  claim 11 , wherein said inner diameter shroud comprises a plurality of counter sunk holes, and wherein a fastener protrudes through each of said plurality of counter sunk holes thereby fastening said fan exit guide vane segment to said frame. 
     
     
         13 . The gas turbine engine of  claim 11 , wherein said outer diameter shroud comprises a plurality of counter sunk holes, and wherein a fastener protrudes through each of said plurality of counter sunk holes thereby fastening said fan exit guide vane segment to an engine casing. 
     
     
         14 . The gas turbine engine of  claim 12 , wherein each of said plurality of fan exit guide segments abuts at least two adjacent fan exit guide vane segments. 
     
     
         15 . The gas turbine engine of  claim 14 , further comprising an integral flow path spacer operable to create a seal between each abutting outer diameter shroud. 
     
     
         16 . The gas turbine engine of  claim 14 , further comprising an integral flow path spacer operable to create a seal between each abutting inner diameter shroud. 
     
     
         17 . The gas turbine engine of  claim 12 , wherein a head of each said fasteners is flush with such counter sunk holes. 
     
     
         18 . The gas turbine engine of  claim 11 , wherein each of said plurality of fan exit guide vanes segments structurally supports said gas turbine engine. 
     
     
         19 . The gas turbine engine of  claim 18 , wherein said gas turbine engine is structurally supported at a gas exit via only said fan exit guide vane segments. 
     
     
         20 . A method for creating a fan exit guide vane segment comprising the steps of creating a fiber preform by looping a fiber in a desired profile; and
 infusing said fiber preform with a resin during a molding process thereby creating a single monolithic fan exit guide vane segment.   
     
     
         21 . The method of  claim 20 , wherein said looped fiber is substantially a structurally continuous loop. 
     
     
         22 . The method of  claim 20 , wherein said looped fiber is substantially a structurally semi-continuous loop. 
     
     
         23 . The method of  claim 20 , wherein said resin is a carbon/epoxy resin.