Manufacturing assembly and method for manufacturing a fan blade

• US 10,639,751 B2
• Filed: 06/25/2018
• Issued: 05/05/2020
• Est. Priority Date: 07/03/2017
• Status: Active Grant

• Current Assignee: Rolls-Royce PLC (Rolls-Royce Holdings Plc)
• Original Assignee: Rolls-Royce PLC (Rolls-Royce Holdings Plc)
• Inventors: Mason, John H.
• Primary Examiner(s): Travers, Matthew P
• Application Number:
  US16/016,735
• Publication Number:
  US 20190001449A1
• Time in Patent Office: 680 Days
• CPC Class Codes: B21D 26/055 Blanks having super-plastic properties
• CPC Class Codes: B21D 26/059 Layered blanks
• CPC Class Codes: B21D 53/78 propeller blades; turbine blades
• CPC Class Codes: B23K 20/02 by means of a press ; Diffusion bonding B23K20/001, B23K20/04 take precedence
• CPC Class Codes: B23K 2101/001 Turbines
• CPC Class Codes: B23P 15/04 turbine or like blades from several pieces
• CPC Class Codes: F01D 5/18 Hollow blades, i.e. blades with cooling or heating channels or cavities structure of hollow blades in general F01D5/147; Heating, heat-insulating or cooling means on blades
• CPC Class Codes: F02K 3/06 with front fan
• CPC Class Codes: F04D 29/388 characterised by construction
• CPC Class Codes: F05D 2220/32 in gas turbines
• CPC Class Codes: F05D 2230/236 Diffusion bonding
• CPC Class Codes: F05D 2230/25 by forging
• CPC Class Codes: F05D 2230/50 Building or constructing in particular ways
• CPC Class Codes: F05D 2240/30 Characteristics of rotor blades, i.e. of any element transforming dynamic fluid energy to or from rotational energy and being attached to a rotor
• CPC Class Codes: F05D 2300/174 Titanium alloys, e.g. TiAl

Abstract

The present disclosure relates to an assembly for formation of a fan blade. The assembly comprises a suction panel; a pressure panel; and a membrane having a leading edge and a trailing edge. The membrane is sandwiched between the suction panel and pressure panel. The membrane comprises a gas entry slot extending in a radial direction, the gas entry slot having a radially outer receiving portion for receiving a pipe, and a radially inner portion. The radially inner portion of the gas entry slot has a substantially uniform width in a direction between the leading and trailing edge of the membrane.

Claims

1. An assembly for formation of a fan blade, the assembly comprising:

a suction panel;

a pressure panel;

a membrane sandwiched between the suction panel and pressure panel, wherein;

the membrane has a leading edge and a trailing edge, and

the membrane comprises a gas entry slot extending in a radial direction, the gas entry slot having a radially outer receiving portion for receiving a pipe, and a radially inner portion wherein the radially inner portion of the gas entry slot has a uniform width in a direction between the leading and trailing edge of the membrane; and

a pipe, having an internal cross-sectional area X, inserted into the receiving portion, wherein the width (W) of the radially inner portion in the direction between the leading and trailing edges is defined by;

W=X/T, where T is the thickness of the membrane.

2. The assembly according to claim 1 wherein the width of the radially inner portion of the gas entry slot in the direction between the leading and trailing edges of the membrane is less than 3 mm.

3. The assembly according to claim 2 wherein the width of the radially inner portion of the gas entry slot in the direction between the leading and trailing edges of the membrane is between 1.1 and 0.8 mm.

4. The assembly according to claim 1 wherein the width (W) of the radially inner portion in the direction between the leading and trailing edges is defined:

W=0.785 mm²/T

where T is the thickness of the membrane.

5. The assembly according to claim 1 wherein the radially inner portion of the gas entry slot comprises a hook portion where the radially inner portion deflects through greater than 90 degrees.

6. The assembly according to claim 5 wherein the radially inner portion deflects through 135 degrees.

7. The assembly according to claim 5 wherein the gas entry slot comprises a meander portion radially outwards of the hook portion.

8. The assembly according to claim 1 wherein the pipe is inserted into the receiving portion to a depth matching a depth of the receiving portion such that the pipe abuts the radially inner portion of the gas entry slot.

9. A method of forming a fan blade comprising providing the assembly according to claim 1 wherein the membrane has a thickness (T) and inserting the pipe having an internal cross-sectional area (X) into the gas entry slot in the membrane,

wherein the radially inner portion has a width (W) in a direction between the leading and trailing edge of the membrane such that:

W=X/T.

10. The method according to claim 9 further comprising bonding peripheries of the pressure panel, suction panel and membrane prior to inserting the pipe.

11. The method according to claim 9 further comprising inserting the pipe into the receiving portion to a depth matching a depth of the receiving portion such that the pipe abuts the radially inner portion of the gas entry slot.

12. The method according to claim 9 comprising flowing gas into the assembly through the pipe in order to inflate the assembly.

13. The method according to claim 9 wherein the method further comprises sealing the gas entry slot.