Method for manufacturing a composite material part comprising a body extended by a reinforced attachment end

Patent metadata

Field	Value
Publication number	US-11141938-B2
Application number	US-201816603643-A
Country	US
Kind code	B2
Filing date	Apr 9, 2018
Priority date	Apr 13, 2017
Publication date	Oct 12, 2021
Grant date	Oct 12, 2021

Abstract

The invention concerns a method for manufacturing a turbomachine flow straightener made from composite material having a blade extended by at least one attachment end, comprising the operations of:forming a fibrous blank from a three-dimensional fabric comprising warp threads oriented in a direction corresponding to the longitudinal direction of the blade to be manufactured;dividing at least one end of the fibrous blank by separating in order to constitute at least two sets of integrated layers;shifting at least one set of integrated layers in a planar configuration such that the warp threads are inclined in this set of integrated layers relative to the orientation of the warp threads in the fibrous blank portion of the blade.

First claim

What is claimed is:

1. Method for manufacturing an aircraft composite material part comprising a body ( 14 ) extended by a reinforced coupling end ( 16 ), comprising the operations of:
forming a fibrous blank ( 13 ) from a three-dimensional fabric comprising warp threads ( 12 ) oriented in a main direction (AR) with separation of at least one end ( 16 ) of the fibrous blank ( 13 ) in order to constitute at least two sets of integrated layers ( 21 , 22 , 23 );
shifting at least one set of integrated layers ( 22 , 23 ) in a planar configuration by offsetting one end edge ( 24 ) of said set of integrated layers ( 22 , 23 ) by applying to said end edge ( 24 ) a shear displacement oriented parallel to the set of integrated layers ( 22 , 23 ) and perpendicular to the main direction (AR), in order to incline the warp threads ( 12 ) of said set of integrated layers ( 22 , 23 ) relative to the main direction (AR);
shaping of the fibrous blank in order to constitute a preform;
injection of a matrix into the preform.

2. Method according to claim 1 , wherein the separation of the fibrous blank is carried out during an operation for weaving the three-dimensional fabric according to a separation plane parallel to the main direction (AR) by arranging a routing of the weft threads ( 11 ) without crossing the separation plane in the reinforced end ( 16 ).

3. Method according to claim 1 , wherein after the shifting operation, the warp threads are inclined by an angular value between +45 degrees and −45 degrees relative to the main direction (AR).

4. Method according to claim 1 , including the application of a means of attachment to a portion of each shifted set of integrated layers in order to hold same in shifted configuration.

5. Method according to claim 1 , including the addition of threads of fibreglass, carbon or Kevlar by sewing or by cross stitching a plurality of shifted sets of integrated layers in order to hold same together.

6. Method according to claim 1 , wherein the coupling end comprises a proportion of weft threads ( 11 ) relative to the warp threads ( 12 ) that is different from the proportion of weft threads ( 11 ) relative to the warp threads ( 12 ) in the body ( 14 ).

7. Method according to claim 1 , wherein the weft threads ( 11 ) have in the reinforced end ( 16 ) a section smaller than the section of the weft threads ( 11 ) in the body ( 14 ).

8. Method according to claim 1 for manufacturing a turbomachine flow straightener ( 1 ) made from composite material including a body forming a blade ( 2 ) extended by at least one attachment coupling end ( 3 , 4 ), wherein the main direction (AR) corresponds to the direction of the body.

9. Method according to claim 8 , wherein the end ( 16 ) is separated into a central set of integrated layers ( 21 ), an upper set of integrated layers ( 22 ) and a lower set of integrated layers ( 23 ), wherein the upper set of integrated layers ( 22 ) and the lower set of integrated layers ( 23 ) are shifted so that the warp threads ( 12 ) of said shifted sets of integrated layers ( 22 , 23 ) are inclined by opposite angles relative to a plane that is normal to the central set of integrated layers ( 21 ) and parallel to the warp threads of the central set of integrated layers ( 21 ).

10. Method according to claim 1 , wherein the end ( 16 ) is separated into a plurality of sets of integrated layers ( 21 , 22 , 23 ), and wherein said sets of integrated layers ( 21 , 22 , 23 ) are shifted in a balanced manner so that the sum of the angles of the warp threads ( 12 ) of each set of integrated layers ( 21 , 22 , 23 ) relative to a plane parallel to the main direction (AR) and normal to said sets of integrated layers is zero.

11. Method according to claim 10 , wherein the separated sets of integrated layers ( 21 , 22 , 23 ) are folded relative to the remainder of the fibrous blank ( 13 ) in order to constitute a coupling end of the straightener ( 1 ), before injection of the matrix.

12. Method according to claim 1 , wherein the end ( 16 ) is separated into a plurality of sets of integrated layers and wherein said sets of integrated layers are shifted symmetrically in order to comprise a plane of symmetry for which each pair of sets of integrated layers located on either side and at same distance from said plane of symmetry comprises warp threads ( 12 ) having the same inclination relative to a plane parallel to the main direction (AR) and normal to said sets of integrated layers.

Assignees

• Safran

Inventors

• Lanfant Nicolas Pierre
• Coupe Dominique Marie Christian
• Faivre D'Arcier Pierre

Classifications

• B29C70/302

  Details of the edges of fibre composites, e.g. edge finishing or means to avoid delamination · CPC title

• B29B11/16

  comprising fillers or reinforcement {(non-woven fabrics per se D04H1/00, D04H3/00)} · CPC title

• B29C70/222

  the structure being shaped to form a three dimensional configuration · CPC title

• B29L2031/08

  Blades for rotors, stators, fans, turbines or the like, e.g. screw propellers · CPC title

• B29C2793/0063

  Cutting longitudinally · CPC title