Composite airfoil with woven insert

• US 5,279,892 A
• Filed: 06/26/1992
• Issued: 01/18/1994
• Est. Priority Date: 06/26/1992
• Status: Expired due to Term

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: Gracias, Brian K., Baldwin, Jack W.
• Primary Examiner(s): Lesmes, George F.
• Assistant Examiner(s): RAIMUND, CHRISTOPHER W
• Application Number:
  US07/904,429
• Time in Patent Office: 571 Days
• Field of Search: 428/232, 428/245, 428/246, 428/257
• US Class Current: 442/206
• 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: B29C 70/24 oriented in at least three directions forming a three dimensional structure
• CPC Class Codes: B29D 99/0025 Producing blades or the like, e.g. blades for turbines, propellers, or wings
• CPC Class Codes: B29L 2031/08 Blades for rotors, stators, fans, turbines or the like, e.g. screw propellers
• CPC Class Codes: B32B 2260/023 Two or more layers
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2262/106 Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2603/00 Vanes, blades, propellers, rotors with blades
• CPC Class Codes: B32B 5/024 Woven fabric
• CPC Class Codes: B32B 5/26 another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: B64C 11/26 Fabricated blades
• CPC Class Codes: F01D 5/282 Selecting composite materials, e.g. blades with reinforcing filaments
• CPC Class Codes: F05D 2300/6034 Orientation of fibres, weaving, ply angle
• CPC Class Codes: Y02T 50/60 Efficient propulsion technologies, e.g. for aircraft
• CPC Class Codes: Y10T 442/3203 Multi-planar warp layers
• CPC Class Codes: Y10T 442/3813 Coating or impregnation contains synthetic polymeric material

Abstract

Inserting a woven composite layer between laminates of composite material layers where the insert layer comprises composite, carbon fibers woven in a three dimensional weave. The woven insert is injected with a resin material and partially cured prior to deposition of the composite layers. The complete blade is then molded and cured as a unit.

Claims

1. A composite airfoil structure comprising:

outer layers of composite prepreg material surrounding a three-dimensional woven insert layer, wherein said woven insert layer includes fiber layers interwoven with strengthening fibers which are arranged to bind said fiber layers together;

said prepreg material comprises carbon fibers coated with a resin compound in a unidirectional sheet; and

said woven insert layer comprises carbon fibers woven in a warp direction woven with carbon fibers in a fill direction at an angle of approximately 90°

to said warp direction and strengthening fibers woven at a through-thickness direction at an angle of approximately 45°

to said warp direction and 90°

to said fill direction.

2. A composite structure according to claim 1 wherein:

said woven insert layer includes spaces between said carbon fibers, and said spaces being filled with an injectable resin compound.

3. A composite airfoil structure comprising:

a three-dimensional woven insert comprising carbon fibers woven in a warp direction woven with carbon fibers in a fill direction at an angle of approximately 90°

to said warp direction and strengthening fibers woven at a through-thickness direction at an angle of approximately 45°

to said warp direction and 90°

to said fill direction;

first and second load transition layers disposed on either side of said woven insert said load transition layers selected from the group consisting of a prepeg, a woven fabric and an adhesive;

a plurality of prepreg layers disposed over said load transition layers;

an outer fabric prepreg layer disposed over said plurality of prepreg layers wherein said outer fabric prepreg layer is larger than said load transition layer and contacts said woven insert.

4. A composite airfoil structure according to claim 3 wherein:

said load transition layer comprises a prepreg layer.

5. A composite airfoil structure according to claim 3 wherein:

said load transition layer comprises a fabric prepreg layer.

6. A composite airfoil structure according to claim 3 wherein:

said load transition layer comprises an adhesive layer adapted to bond said woven insert to said prepreg layers.

7. A composite airfoil according to claim 3 wherein:

said prepreg layers are deposited such that said grain of each layer is rotated approximately 45°

from the grain of a preceding layer.

8. A composite airfoil comprising:

a three-dimensional woven central region including carbon fibers in a warp direction woven with carbon fibers in a fill direction at an angle of approximately 90°

to said warp direction and carbon fibers in a through-thickness direction woven at an angle of approximately 45°

to said warp direction and 90°

to said fill direction and held in place by resin compound;

first and second load transition layers on either side of said woven central region said load transition layers selected from the group consisting of a prepeg, a woven fabric and an adhesive;

prepreg layers comprising carbon fibers coated in resin and arranged in a grain pattern wherein said prepreg layers overlie said load transition layers.