Composite airfoil

Patent metadata

Field	Value
Publication number	US-2016160658-A1
Application number	US-201414905345-A
Country	US
Kind code	A1
Filing date	Jul 1, 2014
Priority date	Jul 15, 2013
Publication date	Jun 9, 2016
Grant date	—

Abstract

An airfoil includes a core with a first Young's Modulus; and an outer section at least partially surrounding the core with a second Young's Modulus, wherein the first Young's Modulus is higher than the second Young's Modulus.

First claim

1 . An airfoil comprising:
a core with a first Young's Modulus; and an outer section at least partially surrounding the core with a second Young's Modulus, wherein the first Young's Modulus is higher than the second Young's Modulus.

2 . The airfoil of claim 1 , wherein the core comprises first fibers.

3 . The airfoil of claim 2 , wherein the first fibers are unidirectional.

4 . The airfoil of claim 2 , wherein the outer section comprises a plurality of two-dimensional plies comprising second fibers.

5 . The airfoil of claim 4 , wherein a Young's Modulus of the first fibers is higher than a Young's Modulus of the second fibers.

6 . The airfoil of claim 5 , further comprising an additional section comprising third fibers, wherein a Young's Modulus of the additional fibers is lower than the Young's Modulus of the second fibers.

7 . The airfoil of claim 1 , wherein the core is a three-dimensional woven core.

8 . The airfoil of claim 1 , wherein the core is a plurality of two-dimensional woven fabric plies.

9 . The airfoil of claim 1 , wherein the core is a molded core.

10 . The airfoil of claim 1 , wherein the core is a uniweave.

11 . The airfoil of claim 1 , wherein the core extends in a spanwise direction.

12 . The airfoil of claim 1 , wherein the outer section forms a leading edge, a trailing edge, a suction side and a pressure side of the airfoil.

13 . The airfoil of claim 1 , wherein the airfoil is a ceramic matric composite or an organic matrix composite.

14 . The airfoil of claim 1 , wherein the airfoil forms a blade or a vane.

15 . A method of forming a composite airfoil, the method comprising:
forming a core with a first Young's Modulus; forming an outer section with a second Young's Modulus; and joining the core with the outer section so that the core is at least partially surrounded by the outer section, wherein the first Young's Modulus is higher than the second Young's Modulus.

16 . The method of claim 15 , wherein the step of forming the core comprises:
forming the core through one of: a plurality of two-dimensional plies formed with first fibers, a mold of a plurality of first fibers and a three-dimensional weave of first fibers.

17 . The method of claim 16 , wherein the first fibers in the plurality of first plies are substantially unidirectional.

18 . The method of claim 16 , wherein the step of forming the outer section comprises:
forming a plurality of plies with second fibers.

19 . The method of claim 18 , wherein a Young's Modulus of the first fibers is higher than a Young's Modulus of the second fibers.

20 . The method of claim 15 , wherein the outer section forms a pressure side, suction side, leading edge and trailing edge of the airfoil.

Assignees

• United Technologies Corp

Inventors

• Mccaffrey Michael G
• Ojard Greg C
• Rugg Kevin L

Classifications

• F01D5/147

  Construction, i.e. structural features, e.g. of weight-saving hollow blades (F01D5/148, F01D5/16 and F01D5/20 take precedence; blade shape F01D5/141; blades with cooling or heating channels or cavities F01D5/18; heating, heat-insulating or cooling means on blades F01D5/18) · CPC title

• F05D2300/6034

  Orientation of fibres, weaving, ply angle · CPC title

• F05D2300/501

  Elasticity · CPC title

• F05D2300/6033

  Ceramic matrix composites [CMC] · CPC title

• F05D2230/60

  Assembly methods · CPC title