Method of manufacturing a composite blade with a reinforced leading edge
First Claim
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1. A method of manufacturing a composite propulsor blade having an axially extending load bearing spar disposed within a fiber reinforced shell defining an airfoil comprising the steps of:
- forming a spar assembly that carries the load absorbed by the propulsive blade having a leading edge, a trailing edge, and a pressure side and a suction side extending therebetween;
wrapping one sheet of fabric material of substantially uniform thickness that is precut to a length exceeding the full extent of the airfoil including the pressure side and suction side defining a blanket about said spar assembly whereby said spar assembly is covered by a fabric wrap by wrapping said one sheet about said spar assembly such that said one sheet overlaps itself at the leading edge so that said fabric wrap has a first relatively uniform thickness overlapping the leading edge of said spar assembly and a second uniform thickness overlapping the remainder of said spar assembly, said first thickness being about twice the thickness as said second thickness; and
impregnating said one sheet of fabric material with a curable resin material whereby upon subsequent curing of the resin material a fiber reinforced shell having an approximately double thick leading edge portion is formed about the spar assembly.
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Abstract
A method of making a shell (30) of a lightweight composite propulsor blade (10) of spar and shell construction having a leading edge portion (39) having twice the thickness as the remainder (33, 35, 37) of the shell thereby enhancing resistance to foreign object damage and improving erosion resistance.
64 Citations
5 Claims
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1. A method of manufacturing a composite propulsor blade having an axially extending load bearing spar disposed within a fiber reinforced shell defining an airfoil comprising the steps of:
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forming a spar assembly that carries the load absorbed by the propulsive blade having a leading edge, a trailing edge, and a pressure side and a suction side extending therebetween; wrapping one sheet of fabric material of substantially uniform thickness that is precut to a length exceeding the full extent of the airfoil including the pressure side and suction side defining a blanket about said spar assembly whereby said spar assembly is covered by a fabric wrap by wrapping said one sheet about said spar assembly such that said one sheet overlaps itself at the leading edge so that said fabric wrap has a first relatively uniform thickness overlapping the leading edge of said spar assembly and a second uniform thickness overlapping the remainder of said spar assembly, said first thickness being about twice the thickness as said second thickness; and impregnating said one sheet of fabric material with a curable resin material whereby upon subsequent curing of the resin material a fiber reinforced shell having an approximately double thick leading edge portion is formed about the spar assembly. - View Dependent Claims (2, 3, 4, 5)
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Specification