CONTAINMENT CASE AND METHOD OF MANUFACTURE

• US 20130153456A1
• Filed: 12/15/2011
• Published: 06/20/2013
• Est. Priority Date: 12/15/2011
• Status: Active Grant

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: Zhu, Qi, Finn, Scott Roger
• Granted Patent: US 9,248,612 B2
• Time in Patent Office: Days
• US Class Current: 206/521
• CPC Class Codes: B29C 70/08 comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
• CPC Class Codes: B29K 2995/0089 Impact strength or toughness
• CPC Class Codes: B29L 2031/7504 Turbines
• CPC Class Codes: F01D 25/24 Casings modified for heating or cooling F01D25/14; Casing parts, e.g. diaphragms, casing fastenings casings for rotary machines or engines in general F16M ; special arrangements in stators dealing with breaking-off of part of rotor F01D21/045
• CPC Class Codes: F01D 5/28 Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
• CPC Class Codes: F01D 5/282 Selecting composite materials, e.g. blades with reinforcing filaments
• CPC Class Codes: Y02T 50/60 Efficient propulsion technologies, e.g. for aircraft

Abstract

A containment case comprises a composite core, with an inner and outer surface, at least one puncture resistant layer bonded to the inner surface of the composite core and at least one energy capture layer bonded to the outer surface of the composite core. The puncture resistant layer having a high through-thickness shear strength and high interlaminar toughness at impact. The energy capture layer having a high in-plane tensile strength and low resistance to delamination and fiber-matrix debonding at impact. A method of fabricating a containment case includes the steps of disposing one or more layers of a puncture resistant material on a layup mandrel, disposing one more layers of a structural composite material on an exterior surface of the puncture resistant material, disposing one or more layers of an energy capture material on an exterior surface of the structural material and curing a resin in the plurality of layers.

Claims

1. A containment case comprising:

a composite core having an inner surface and an outer surface;

at least one puncture resistant layer integrated with the composite core, wherein the at least one puncture resistant layer includes a resin to bond the at least one puncture resistant layer to the inner surface of the composite core; and

at least one energy capture layer integrated with the composite core, wherein the at least one energy capture layer includes a resin to bond the at least one energy capture layer to the outer surface of the composite core.

2. The containment case of claim 1, wherein the at least one puncture resistant layer comprises a fiber and resin material with high through-thickness shear strength and high interlaminar toughness at impact.

3. The containment case of claim 2, wherein the at least one puncture resistant layer comprises at least one of a nonwoven fabric, a wrap, a blanket, a winding, a woven fabric, a knitted fabric, a carded non-woven fabric, or a braided fabric.

4. The containment case of claim 3, wherein the at least one puncture resistant layer comprises fibers comprised of at least one of S2 glass, E-glass, quartz, alumina, silica, boron oxide, or carbon and a resin with high fracture toughness.

5. The containment case of claim 4, wherein the at least one puncture resistant layer comprises S2 glass fibers and a dicyclopentadiene (DCPD) resin.

6. The containment case of claim 1, wherein the at least one energy capture layer comprises a fiber and resin material with high in-plane tensile strength and low resistance to delamination and fiber-matrix debonding.

7. The containment case of claim 6, wherein the at least one energy capture layer comprises at least one of a nonwoven fabric, a wrap, a blanket, a winding, a woven fabric, a knitted fabric, a carded non-woven fabric, or a braided fabric.

8. The containment case of claim 7, wherein the at least one energy capture layer comprises fibers comprised of at least one of graphite, carbon, polyimide, aromatic polyamide, or ultra-high molecular weight polyethylene and a resin that does not bond well with the fibers to facilitate delamination and fiber-matrix debonding.

9. The containment case of claim 8, wherein the at least one energy capture layer further comprises at least one of a fiber sizing or surface treatment for minimizing fiber-to-resin adhesion.

10. The containment case of claim 8, wherein the at least one energy capture layer comprises carbon fibers and a dicyclopentadiene (DCPD) resin.

11. The containment case of claim 1, wherein the at least one puncture resistant layer comprises S2 glass fibers and a dicyclopentadiene (DCPD) resin and the at least one energy capture layer comprises carbon fibers and a dicyclopentadiene (DCPD) resin.

12. The containment case of claim 1, wherein the composite core comprises a reinforcing fabric.

13. The containment case of claim 12, wherein the composite core further includes reinforcement stitching to control delamination upon impact.

14. A containment case comprising:

a composite core with an inner surface and an outer surface;

at least one puncture resistant layer disposed in a primary impact zone and integrated with the composite core, wherein the at least one puncture resistant layer is configured coextensive with a length of the composite core and includes a resin to bond the at least one puncture resistant layer to the inner surface of the composite core, the at least one puncture resistant layer characterized by a high through-thickness shear strength and a high interlaminar toughness at impact; and

at least one energy capture layer disposed in a primary impact zone and integrated with the composite core, wherein the at least one energy capture layer is configured coextensive with a length of the composite core and includes a resin to bond the at least one energy capture layer to the outer surface of the composite core, the at least one energy capture layer characterized by a high in-plane tensile strength and low resistance to delamination and fiber-matrix debonding at impact.

15. The containment case of claim 14, wherein the at least one puncture resistant layer comprises fibers comprised of S2 glass, E-glass, quartz, alumina, silica, boron oxide, or carbon fibers and a resin with high fracture toughness.

16. The containment case of claim 15, wherein the at least one puncture resistant layer comprises S2 glass fibers and a dicyclopentadiene (DCPD) resin.

17. The containment case of claim 14, wherein the at least one energy capture layer comprises fibers comprised of at least one of graphite, carbon, polyimide, aromatic polyamide, or ultra-high molecular weight polyethylene and a resin that does not bond well with the fibers to facilitate delamination and fiber-matrix debonding.

18. The containment case of claim 17, wherein the at least one energy capture layer comprises carbon fibers and a dicyclopentadiene (DCPD) resin.

19. The containment case of claim 14, wherein the at least one puncture resistant layer comprises S2 glass fibers and a dicyclopentadiene (DCPD) resin and the at least one energy capture layer comprises carbon fibers and a dicyclopentadiene (DCPD) resin.

23. The method of claim 19, wherein the one or more layers of the energy capture material comprises fibers comprised of at least one of graphite, carbon, polyimide, aromatic polyamide, or ultra-high molecular weight polyethylene and a resin that does not bond well with the fibers to facilitate delamination and fiber-matrix debonding.

24. The method of claim 19, further including a step of at least partially curing a resin in the composite core and the one or more layers of the puncture resistant material, prior to disposing one or more layers of an energy capture material on an exterior surface of the structural material.

20. A method of fabricating a containment case, the method comprising:

disposing one or more layers of a puncture resistant material on a layup mandrel;

disposing one more layers of a structural composite material on an exterior surface of the puncture resistant material;

disposing one or more layers of an energy capture material on an exterior surface of the structural material; and

curing a resin in the composite core, the one or more layers of the puncture resistant material and the one or more layers of the energy capture material.

21. The method of claim 20, further comprising infusing the composite core, the one or more layers of the puncture resistant material and the one or more layers of the energy capture material with resin.

22. The method of claim 20, wherein the one or more layers of the puncture resistant material comprises fibers comprised of S2 glass, E-glass, quartz, alumina, silica, boron oxide, or carbon fibers and a resin with high fracture toughness.