Cylindrical case and manufacturing method of cylindrical case

Patent metadata

Field	Value
Publication number	US-9988156-B2
Application number	US-201514696073-A
Country	US
Kind code	B2
Filing date	Apr 24, 2015
Priority date	Oct 25, 2012
Publication date	Jun 5, 2018
Grant date	Jun 5, 2018

Abstract

A cylindrical case includes a case main body, and a groove disposed annularly at one end of the case main body. A peripheral wall of the case main body is formed by alternately laminating a biaxial fabric layer, which includes a biaxial fabric of a non-crimp structure composed of reinforcing fiber bands having an orientation angle of ±45°, and a roving layer. A groove wall of the groove is formed by alternately laminating the biaxial fabric layer, which continues to the case main body side, and a triaxial fabric layer, which includes a triaxial fabric of a non-crimp structure composed of reinforcing fiber bands having an orientation angle of ±45° and a reinforcing fiber band having an orientation angle of 0°.

First claim

The invention claimed is:

1. A cylindrical case made of a composite material of reinforcing fibers impregnated with a thermosetting resin, the cylindrical case comprising:
a case main body forming a cylindrical shape; and
a groove which is disposed at one end of the case main body annularly along a circumferential direction and is open to a distal side, wherein
a peripheral wall of the case main body is formed by alternately laminating a plurality of biaxial fabric layers, which include a biaxial fabric of a non-crimp structure composed of two axes of reinforcing fiber bands having an orientation angle of ±15-75° to an axial direction of the case main body, and a plurality of roving layers, which include a roving composed of a bundle of reinforcing fibers extending along the circumferential direction of the case main body, and
a groove wall of the groove is formed by alternately laminating a plurality of biaxial fabric layers, which continue to the plurality of biaxial fabric layers in the peripheral wall of the case main body, and plurality of triaxial fabric layers, which include a triaxial fabric of a non-crimp structure composed of total three axes of reinforcing fiber bands: two axes of reinforcing fiber bands having an orientation angle of ±15-75° to the axial direction of the case main body, and one axis of reinforcing fiber band having an orientation angle of 0° to the axial direction of the case main body.

2. The cylindrical case according to claim 1 , wherein the groove wall of the groove is coated with a Ti-alloy or Ni-alloy cover, and the cylindrical case is used as a fan case for covering fan blades of an aircraft jet engine.

3. The cylindrical case according to claim 1 , wherein front and back surfaces of each of the peripheral wall of the case main body and the groove wall of the groove are all coated with a protective film made of a composite material of reinforcing fibers impregnated with a thermosetting resin.

4. The cylindrical case according to claim 3 , wherein the groove wall of the groove is coated with a Ti-alloy or Ni-alloy cover, and the cylindrical case is used as a fan case for covering fan blades of an aircraft jet engine.

5. A manufacturing method of the cylindrical case according to claim 1 , including:
molding a laminate having a part corresponding to the case main body by repeatedly performing the following steps:
a biaxial fabric layer forming step of rotating a cylindrical mandrel, of which the outer peripheral surface serves as a molding surface, on its axis while winding the biaxial fabric of a non-crimp structure composed of the two axes of reinforcing fiber bands around the molding surface of the mandrel to form the biaxial fabric layers;
a roving layer forming step of rotating the mandrel on its axis while winding the roving composed of a bundle of reinforcing fibers spirally around a case main body molding portion in the molding surface of the mandrel along a circumferential direction to form the roving layers; and
a triaxial fabric layer forming step of rotating the mandrel on its axis while winding the triaxial fabric of a non-crimp structure composed of the three axes of reinforcing fiber bands around a groove molding portion in the molding surface of the mandrel to form the triaxial fabric layers; and
thereafter going through the following steps:
a groove molding step of molding a part corresponding to the groove at the end of the part corresponding to the case main body in the laminate by means of a groove molding die and a groove molding part located at the end of the mandrel; and
a heating step of heating the laminate, in which the part corresponding to the groove is molded at the end of the part corresponding to the case main body in the groove molding step, to thereby cure the thermosetting resin with which the reinforcing fibers of each of the fabric layers are impregnated.

6. A manufacturing method of the cylindrical case according to claim 3 , including:
molding a laminate having a part corresponding to the case main body by repeatedly performing the following steps:
a biaxial fabric layer forming step of rotating a cylindrical mandrel, of which the outer peripheral surface serves as a molding surface, on its axis while winding the biaxial fabric of a non-crimp structure composed of the two axes of reinforcing fiber bands around the molding surface of the mandrel to form the biaxial fabric layers;
a roving layer forming step of rotating the mandrel on its axis while winding the roving composed of a bundle of reinforcing fibers spirally around a case main body molding portion in the molding surface of the mandrel along a circumferential direction to form the roving layers; and
a triaxial fabric layer forming step of rotating the mandrel on its axis while winding the triaxial fabric of a non-crimp structure composed of the three axes of reinforcing fiber bands around a groove molding portion in the molding surface of the mandrel to form the triaxial fabric layers; and
thereafter going through the following steps:
a groove molding step of molding a part corresponding to the groove at the end of the part corresponding to the case main body in the laminate by means of a groove molding die and a groove molding part located at the end of the mandrel; and
a heating step of heating the laminate, in which the part corresponding to the groove is molded at the end of the part corresponding to the case main body in the groove molding step, to thereby cure the thermosetting resin with which the reinforcing fibers of each of the fabric layers are impregnated.

7. A manufacturing method of the cylindrical case according to claim 2 , including:
molding a laminate having a part corresponding to the case main body by repeatedly performing the following steps:
a biaxial fabric layer forming step of rotating a cylindrical mandrel, of which the outer peripheral surface serves as a molding surface, on its axis while winding the biaxial fabric of a non-crimp structure composed of the two axes of reinforcing fiber bands around the molding surface of the mandrel to form the biaxial fabric layers;
a roving layer forming step of rotating the mandrel on its axis while winding the roving composed of a bundle of reinforcing fibers spirally around a case main body molding portion in the molding surface of the mandrel along a circumferential direction to form the roving layers; and
a triaxial fabric layer forming step of rotating the mandrel on its axis while winding the triaxial fabric of a non-crimp structure composed of the three axes of reinforcing fiber bands around a groove molding portion in the molding surface of the mandrel to form the triaxial fabric layers; and
thereafter going through the following steps:
a groove molding step of molding a part corresponding to the groove at the end of the part corresponding to the case main body in the laminate by means of a groove molding die and a groove molding part located at the end of the mandrel; and
a heating step of heating the laminate, in which the part corresponding to the groove is molded at the end of the part corresponding to the case main body in the groove molding step, to thereby cure the thermosetting resin with which the reinforcing fibers of each of the fabric layers are impregnated.

8. A manufacturing method of the cylindrical case according to claim 4 , including:
molding a laminate having a part corresponding to the case main body by repeatedly performing the following steps:
a biaxial fabric layer forming step of rotating a cylindrical mandrel, of which the outer peripheral surface serves as a molding surface, on its axis while winding the biaxial fabric of a non-crimp structure composed of the two axes of reinforcing fiber bands around the mold

Assignees

• Ihi Corp
• Ihi Aerospace Co Ltd

Inventors

• Tanaka Agamu
• Morita Hideo
• Okumura Ikuo
• Shigenari Yuu
• Harada Takashi
• Dan Yusuke

Classifications

• B29C33/301

  Modular mould systems [MMS], i.e. moulds built up by stacking mould elements, e.g. plates, blocks, rods (B29C33/0088 takes precedence) · CPC title

• B29L2022/00

  Hollow articles (tubular articles B29L2023/00; pneumatic tyres B29L2030/00) · CPC title

• B29L2031/772

  Articles characterised by their shape and not otherwise provided for (closed loop B29L2031/709; ring-like B29L2031/7096; corrugated B29L2016/00, flat B29L2007/00; hollow B29L2022/00; screw-threaded B29L2001/00; toothed B29L2031/775; corrugated tubes B29L2023/18) · CPC title

• B29L2023/003

  having irregular or rough surfaces · CPC title

• B64D29/02 Primary

  associated with wings · CPC title