METHOD AND SYSTEM FOR MANUFACTURING A BLADE

• US 20100028594A1
• Filed: 07/31/2008
• Published: 02/04/2010
• Est. Priority Date: 07/31/2008
• Status: Active Grant

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: Crall, David, Kirkeng, Kevin Lee, Davis, Tod, McAfee, Christopher Lee, Franks, Michael John, Kray, Nicholas Joseph
• Granted Patent: US 8,123,463 B2
• Time in Patent Office: Days
• US Class Current: 428/114
• CPC Class Codes: F01D 5/282 Selecting composite materials, e.g. blades with reinforcing filaments
• CPC Class Codes: F04D 29/023 especially adapted for elastic fluid pumps
• CPC Class Codes: F04D 29/324 Blades
• CPC Class Codes: F04D 29/388 characterised by construction
• CPC Class Codes: F05D 2300/6034 Orientation of fibres, weaving, ply angle
• CPC Class Codes: Y10T 156/17 Surface bonding means and/or assemblymeans with work feeding or handling means
• CPC Class Codes: Y10T 29/49332 Propeller making
• CPC Class Codes: Y10T 29/49337 Composite blade
• CPC Class Codes: Y10T 428/24132 including grain, strips, or filamentary elements in different layers or components parallel

Abstract

A method of manufacturing a blade is provided. The method includes providing a plurality of first plies, each of the first plies sized to extend substantially the length of a span of the blade and providing a plurality of second plies, each of the second plies sized to extend only partially the length of the span of the blade. The method also includes layering the plurality of first plies and the plurality of second plies in a mold such that the plurality of second plies is interspersed throughout the plurality of first plies to spread apart the plurality of first plies to facilitate increasing a cross-sectional area of the blade and bonding the plurality of first plies to the plurality of second plies to facilitate forming a structural core of the blade.

Claims

1. A method of manufacturing a blade, said method comprising:

providing a plurality of first plies, each of the first plies sized to extend substantially the length of a span of the blade;

providing a plurality of second plies, each of the second plies sized to extend only partially the length of the span of the blade;

layering the plurality of first plies and the plurality of second plies such that the plurality of second plies is interspersed throughout the plurality of first plies to spread apart the plurality of first plies to facilitate increasing a cross-sectional area of the blade; and

bonding the plurality of first plies to the plurality of second plies to facilitate forming a structural core of the blade.

2. A method in accordance with claim 1, wherein said layering the plurality of first plies and the plurality of second plies comprises interspersing the plurality of second plies in groups of adjacent second plies, each group having a tapered tip that facilitates reducing a resin pocket formation in the structural core of the blade.

3. A method in accordance with claim 2, wherein providing a plurality of first plies comprises providing each first ply with a first thickness, and wherein providing a plurality of second plies comprises providing each second ply with a second thickness, the first thickness being greater than the second thickness to facilitate reducing a resin pocket formation in the structural core of the blade.

4. A method in accordance with claim 1, wherein providing a plurality of first plies comprises providing each of the first plies with an arrangement of composite fibers oriented in the same direction relative to an axis of the first ply, and wherein providing a plurality of second plies comprises providing each of the second plies with an arrangement of composite fibers oriented in the same direction relative to an axis of the second ply.

5. A method in accordance with claim 4, wherein layering the plurality of first plies and the plurality of second plies comprises:

layering the plurality of first plies in sets, wherein each set of first plies has a first directional stacking sequence; and

layering the plurality of second plies in sets, wherein each set of second plies has a second directional stacking sequence that is different than the first directional stacking sequence.

6. A method in accordance with claim 5, wherein layering the plurality of first plies in sets comprises layering each set of first plies such that at least two of the first plies in the set have composite fiber orientations that differ from one another relative to an axis of the mold, and wherein layering the plurality of second plies in sets comprises layering each set of second plies such that at least two of the second plies in the set have composite fiber orientations that differ from one another relative to an axis of the mold.

7. A method in accordance with claim 5, wherein layering the plurality of first plies in sets comprises repeating the first directional stacking sequence throughout the blade for every set of first plies, and wherein layering the plurality of second plies in sets comprises repeating the second directional stacking sequence throughout the blade for every set of second plies.

8. A system for manufacturing a blade, said system comprising:

a mold;

a plurality of first plies, each of said first plies sized to extend substantially the length of a span of the blade;

a plurality of second plies, each of said second plies sized to extend only partially the length of the span of the blade, said plurality of first plies layered with said plurality of second plies in said mold such that said plurality of second plies is interspersed throughout said plurality of first plies to spread apart said plurality of first plies to facilitate increasing a cross-sectional area of the blade.

9. A system in accordance with claim 8, wherein said plurality of second plies are interspersed throughout said plurality of first plies in groups of adjacent second plies, each group comprising a tapered tip that facilitates reducing a resin pocket formation in the blade.

10. A system in accordance with claim 9, wherein each of said first plies comprises a first thickness, each of said second plies comprising a second thickness, the first thickness being greater than the second thickness to facilitate reducing a resin pocket formation in the blade.

11. A system in accordance with claim 8, wherein each of said first plies comprises an arrangement of composite fibers oriented in the same direction relative to an axis of said first ply, each of said second plies comprising an arrangement of composite fibers oriented in the same direction relative to an axis of said second ply.

12. A system in accordance with claim 11, wherein said first plies are layered in sets, each set of first plies comprising a first directional stacking sequence, said second plies layered in sets, wherein each set of second plies comprises a second directional stacking sequence that is different than said first directional stacking sequence.

13. A system in accordance with claim 12, wherein each set of first plies comprises at least two first plies comprising composite fiber orientations that differ from one another relative to an axis of said mold, each set of second plies comprising at least two second plies comprising composite fiber orientations that differ from one another relative to an axis of said mold.

14. A system in accordance with claim 12, wherein said first directional stacking sequence is repeated throughout the blade for every set of first plies, and wherein said second directional stacking sequence is repeated throughout the blade for every set of second plies.

15. A blade comprising:

a plurality of first plies, each of said first plies sized to extend substantially the length of a span of said blade;

a plurality of second plies, each of said second plies sized to extend only partially the length of the span of said blade, said plurality of first plies layered with said plurality of second plies such that said plurality of second plies is interspersed throughout said plurality of first plies to spread apart said plurality of first plies to facilitate increasing a cross-sectional area of said blade, said plurality of first plies bonded to said plurality of second plies.

16. A blade in accordance with claim 15, wherein said plurality of second plies are interspersed throughout said plurality of first plies in groups of adjacent second plies, each group comprising a tapered tip.

17. A blade in accordance with claim 16, wherein each of said first plies comprises a first thickness, each of said second plies comprising a second thickness, the first thickness being greater than the second thickness.

18. A blade in accordance with claim 15, wherein each of said first plies comprises an arrangement of composite fibers oriented in the same direction relative to an axis of said first ply, each of said second plies comprising an arrangement of composite fibers oriented in the same direction relative to an axis of said second ply.

19. A blade in accordance with claim 18, wherein said first plies are layered in sets, each set of first plies comprising a first directional stacking sequence, said second plies layered in sets, wherein each set of second plies comprises a second directional stacking sequence that is different than said first directional stacking sequence.

20. A blade in accordance with claim 19, wherein said first directional stacking sequence is repeated throughout said blade for every set of first plies, and wherein said second directional stacking sequence is repeated throughout said blade for every set of second plies.