GB2064412A - Moulding Perforated Structures - Google Patents
Moulding Perforated Structures Download PDFInfo
- Publication number
- GB2064412A GB2064412A GB7941195A GB7941195A GB2064412A GB 2064412 A GB2064412 A GB 2064412A GB 7941195 A GB7941195 A GB 7941195A GB 7941195 A GB7941195 A GB 7941195A GB 2064412 A GB2064412 A GB 2064412A
- Authority
- GB
- United Kingdom
- Prior art keywords
- resin
- composite structure
- sheet
- making
- former
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
- 238000000465 moulding Methods 0.000 title description 2
- 239000011347 resin Substances 0.000 claims abstract description 45
- 229920005989 resin Polymers 0.000 claims abstract description 45
- 239000002131 composite material Substances 0.000 claims abstract description 31
- 238000004519 manufacturing process Methods 0.000 claims abstract description 14
- 239000000835 fiber Substances 0.000 claims abstract description 13
- 150000001875 compounds Chemical class 0.000 claims abstract description 3
- 229920005992 thermoplastic resin Polymers 0.000 claims abstract description 3
- 229920001169 thermoplastic Polymers 0.000 claims description 7
- 239000004416 thermosoftening plastic Substances 0.000 claims description 7
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 4
- 229910052799 carbon Inorganic materials 0.000 claims description 4
- 238000005553 drilling Methods 0.000 claims description 3
- 238000004080 punching Methods 0.000 claims description 3
- 239000003365 glass fiber Substances 0.000 claims description 2
- 239000000203 mixture Substances 0.000 abstract description 3
- 229920001187 thermosetting polymer Polymers 0.000 abstract description 3
- 238000000034 method Methods 0.000 description 8
- 239000011159 matrix material Substances 0.000 description 3
- 239000011521 glass Substances 0.000 description 2
- OWYWGLHRNBIFJP-UHFFFAOYSA-N Ipazine Chemical compound CCN(CC)C1=NC(Cl)=NC(NC(C)C)=N1 OWYWGLHRNBIFJP-UHFFFAOYSA-N 0.000 description 1
- 229920000914 Metallic fiber Polymers 0.000 description 1
- 230000002745 absorbent Effects 0.000 description 1
- 239000002250 absorbent Substances 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 229920002492 poly(sulfone) Polymers 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 238000011144 upstream manufacturing Methods 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B64—AIRCRAFT; AVIATION; COSMONAUTICS
- B64D—EQUIPMENT FOR FITTING IN OR TO AIRCRAFT; FLIGHT SUITS; PARACHUTES; ARRANGEMENT OR MOUNTING OF POWER PLANTS OR PROPULSION TRANSMISSIONS IN AIRCRAFT
- B64D33/00—Arrangements in aircraft of power plant parts or auxiliaries not otherwise provided for
- B64D33/02—Arrangements in aircraft of power plant parts or auxiliaries not otherwise provided for of combustion air intakes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
- B29C67/0011—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 for shaping plates or sheets
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02C—GAS-TURBINE PLANTS; AIR INTAKES FOR JET-PROPULSION PLANTS; CONTROLLING FUEL SUPPLY IN AIR-BREATHING JET-PROPULSION PLANTS
- F02C7/00—Features, components parts, details or accessories, not provided for in, or of interest apart form groups F02C1/00 - F02C6/00; Air intakes for jet-propulsion plants
- F02C7/04—Air intakes for gas-turbine plants or jet-propulsion plants
- F02C7/045—Air intakes for gas-turbine plants or jet-propulsion plants having provisions for noise suppression
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/748—Machines or parts thereof not otherwise provided for
- B29L2031/7504—Turbines
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B64—AIRCRAFT; AVIATION; COSMONAUTICS
- B64D—EQUIPMENT FOR FITTING IN OR TO AIRCRAFT; FLIGHT SUITS; PARACHUTES; ARRANGEMENT OR MOUNTING OF POWER PLANTS OR PROPULSION TRANSMISSIONS IN AIRCRAFT
- B64D33/00—Arrangements in aircraft of power plant parts or auxiliaries not otherwise provided for
- B64D33/02—Arrangements in aircraft of power plant parts or auxiliaries not otherwise provided for of combustion air intakes
- B64D2033/0206—Arrangements in aircraft of power plant parts or auxiliaries not otherwise provided for of combustion air intakes comprising noise reduction means, e.g. acoustic liners
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B64—AIRCRAFT; AVIATION; COSMONAUTICS
- B64D—EQUIPMENT FOR FITTING IN OR TO AIRCRAFT; FLIGHT SUITS; PARACHUTES; ARRANGEMENT OR MOUNTING OF POWER PLANTS OR PROPULSION TRANSMISSIONS IN AIRCRAFT
- B64D33/00—Arrangements in aircraft of power plant parts or auxiliaries not otherwise provided for
- B64D33/02—Arrangements in aircraft of power plant parts or auxiliaries not otherwise provided for of combustion air intakes
- B64D2033/0266—Arrangements in aircraft of power plant parts or auxiliaries not otherwise provided for of combustion air intakes specially adapted for particular type of power plants
- B64D2033/0286—Arrangements in aircraft of power plant parts or auxiliaries not otherwise provided for of combustion air intakes specially adapted for particular type of power plants for turbofan engines
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2250/00—Geometry
- F05D2250/10—Two-dimensional
- F05D2250/19—Two-dimensional machined; miscellaneous
- F05D2250/191—Two-dimensional machined; miscellaneous perforated
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T50/00—Aeronautics or air transport
- Y02T50/60—Efficient propulsion technologies, e.g. for aircraft
Landscapes
- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Combustion & Propulsion (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Aviation & Aerospace Engineering (AREA)
- Composite Materials (AREA)
- Moulding By Coating Moulds (AREA)
Abstract
A method of making a perforated composite structure 16 including a compound curve comprises, making a fibre reinforced perforated resin sheet, curing the resin within the sheet, laying the perforated cured sheet upon a former and subjecting it to heat and pressure such that it conforms to the shape of the former. The resin of the sheet preferably comprises a mixture of thermosetting and thermoplastic resin. <IMAGE>
Description
SPECIFICATION
Composite Structure
This invention relates to a fibre reinforced composite structure suitable for the manufacture of gas turbine engine parts; and more particularly to such structures which may be perforated and are non-planar.
It is well known, that in the past few years gas turbine engines have been made with increasingly larger power output such as to be capable of providing sufficient thrust for the propulsion of progressively larger aircraft demanded by aircraft operators.
This has led to the engines becoming progressively heavier. During this time engine designers have been attempting to design engines as lightweight as possible by using relatively thin section conventional structures and lighweight alloys where appropriate or in certain instances composite structures.
Such composite structures have usually been manufactured from fibres, for example glass or carbon fibres together within a resin matrix. To enable such structures to be used in the manufacture of gas turbine parts such as for example a gas turbine engine intake it has been necessary to lay-up, or filament wind the fibre onto a former corresponding to the finished shape of the component.
However this method is not really practical if it is desired to subsequently perforate the component to enable it to be used as the skin of a sound absorbent lining, as it would not be possible to punch out or drill the perforations quickly and conveniently. One alternative to this process previously known to the applicants has been to provide upstanding projections on the mould to produce the perforations during manufacture of the structure but this has not in fact proved very practical.
The object of the present invention is to produce a perforate composite structure by a method which substantially eliminates the aforementioned problems.
According to the present invention a method of making a composite structure comprises,
making a fibre reinforced resin sheet,
curing the said resin within the sheet,
perforating the sheet with a plurality of holes,
laying the perforated sheet upon a former and subjecting it to heat and pressure such that it conforms to the shape of the former,
and subsequently removing the shaped composite structure from the former.
Preferably the resin consists of a major proportion of thermosetting resin and a minor proportion of thermo-plastic resin.
Preferably the thermo-plastic resin forms between 5 and 40% of the total resin within the structure.
The fibre reinforced resin sheet comprises at least one layer of carbon or glass fibre which may be impregnated within the resin and subsequently cured.
Alternatively the at least one fibre layer may be placed within a mould and injected with resin which resin is subsequently cured.
Preferably the cured fibre reinforced resin sheet is perforated by means of punching or drilling.
Preferably the composite structure comprises a gas turbine part such as for example an engine intake skin or panel.
For better understanding thereof an embodiment of the invention will now be more particularly described by way of example only and with reference to the accompanying drawings in which:
Figure 1 shows a pictorial view of a gas turbine engine incorporating a composite made in accordance with the present invention,
Figures 2 and 3 each show enlarged views of the composite in greater detail.
Referring to Figure 1 of the drawings a gas turbine engine shown generally at 10 comprises a front fan 12 secured at the upstream end of a core engine and arranged within a fan duct formed between an outer portion of the core engine and a fan cowl 14. The fan cowl 14 includes an inner sound-absorbing portion shown generally at 15 which includes a perforate composite layer 16 made in accordance with an embodiment of the present invention.
The perforate composite layer 16 consists of one or more layers of fibre which are secured together within a resin matrix. The fibres in the particular example consist of carbon fibres however the invention is not restricted to the use of such fibres glass, or metallic fibres or for that matter any other fibre having a reasonably high tensile strength could be used.
The fibres may be laid-up in a mould to form the desired area and thickness of sheet in the form of resin impregnated tows or sheets or, the sheets or tows may be laid-up dry and subsequently resin injected to form necessary resin matrix. Alternatively any other conventional lay-up method can be used.
In order to ensure subsequent satisfactory shaping of the sheet it is necessary that the resin consists of a mixture of thermo-plastic and thermo-setting resin. The particular resin at present used consists of a mixture of epoxy resin and polysulphone sold under the name Fibredux 914 (this name being registered trademark of which Ciba Geigy are the proprietors). However it is not intended that this invention be restricted to such resin as there are many other thermo-plastic and thermo-setting resins which could be substituted and the characteristics of which are well known to those skilled in the art.
After the laying-up and if necessary the subsequent resin injection of the fibres, the composite is subjected to both pressure and heat in order that it is both consolidated and fully cured.
The composite sheet is subsequently provided with its necessary perforations by punching, drilling or alternatively any other conventional machining process. Alternatively the perforations may be included or formed within the composite during the laying-up, or moulding process.
After the composite sheet has been perforated it may be formed to its finished shape upon a former by being subjected to both heat and pressure. The most convenient method of carrying out this operation is to enclose the composite within a vacuum bag then arranging it within an autoclave or oven such as to provide the necessary heat pressure to the composite to carry out the forming process. However the forming may be carried out by any other conventional method.
It will be appreciated by those skilled in the art that it is possible to provide a degree of deformation to a fully cured composite which includes only a thermo-setting resin. However the degree of deformation would only be very slight otherwise the mechanical integrity of the resin would be destroyed. However it has been found that with the addition of a proportion of thermoplastic resin; ranging between 5 to 40% of the resin content will ensure that the composite structure may be readily deformed to produce a compound shape without impairing the strength characteristics of the resin.
It would appear that a simple alternative to the present invention would be simply to eliminate a thermo-setting resin from the structure and replace this with thermo-plastic resin. However this would be totally impractical as thermosetting resin has not the resistance to high temperatures and solvents etc. which thermoplastic has.
It will be appreciated that whilst the described embodiment of the present invention has been particularly directed to the manufacture of a portion of a gas turbine engine fan duct, it is not intended that the scope of the invention is restricted to such an application. This method of manufacture may equally successfully be applied to the production of any composite structure having such a shape where the aforementioned problems are encountered.
Claims (9)
1. A method of making a composite structure comprising, making a fibre reinforced resin sheet, curing the said resin within the sheet, perforating the sheet with a plurality of holes, laying the perforated sheet upon a former and subjecting it to heat and pressure such that it conforms to the shape of the former, and subsequently removing the shaped structure from the former.
2. A method of making a composite structure as claimed in claim 1 in which the resin consists of a major proportion of thermo-setting resin and a minor proportion of thermo-plastic resin.
3. A method of making a composite structure as claimed in claims 1 and 2 in which the thermoplastic resin forms between 5 and 40% of the total resin within the structure.
4. A method of making a composite structure as claimed in any preceding claim in which the fibre reinforced resin sheet comprises at least one layer of carbon or glass fibre which may be impregnated with the resin which resin is subsequently cured.
5. A method of making a composite structure as claimed in claim 4 in which the at least one fibre layer may be placed within a mould and injected with resin, which resin is subsequently cured.
6. A method of making a composite structure as claimed in any preceding claim in which the cured fibre reinforced resin sheet is perforated by means of punching or drilling.
7. A composite structure as claimed in any preceding claim comprising a compound shaped gas turbine engine part.
8. A composite structure as claimed in any preceding claim in which the gas turbine engine part comprises a gas turbine engine intake skin or panel.
9. A composite structure as claimed in any preceding claim substantially as hereinbefore described by way of example only and with
reference to the accompanying drawings.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB7941195A GB2064412A (en) | 1979-11-29 | 1979-11-29 | Moulding Perforated Structures |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB7941195A GB2064412A (en) | 1979-11-29 | 1979-11-29 | Moulding Perforated Structures |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| GB2064412A true GB2064412A (en) | 1981-06-17 |
Family
ID=10509480
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB7941195A Withdrawn GB2064412A (en) | 1979-11-29 | 1979-11-29 | Moulding Perforated Structures |
Country Status (1)
| Country | Link |
|---|---|
| GB (1) | GB2064412A (en) |
Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5141690A (en) * | 1989-02-24 | 1992-08-25 | The British Petroleum Company P.L.C. | Method for manufacturing composite material |
| US5252279A (en) * | 1991-01-17 | 1993-10-12 | Reinhold Industries | Method for making perforated articles |
| JP2007309326A (en) * | 2006-05-19 | 2007-11-29 | United Technol Corp <Utc> | Liner assembly for aircraft engine housing and method for attenuating noise in aircraft engine housing |
| EP2463197A1 (en) * | 2010-12-09 | 2012-06-13 | Airbus Operations (Société par actions simplifiée) | Air intake for propulsion system of an aircraft with a structure withstanding overpressure and method for repairing an air intake of an aircraft propulsion system |
| WO2013007937A3 (en) * | 2011-07-13 | 2013-03-28 | Snecma | Method for manufacturing a turbine-engine fan casing having an acoustic coating |
| CN109606708A (en) * | 2018-12-03 | 2019-04-12 | 江西洪都航空工业集团有限责任公司 | A kind of small size inlet structure preparation method |
-
1979
- 1979-11-29 GB GB7941195A patent/GB2064412A/en not_active Withdrawn
Cited By (13)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5141690A (en) * | 1989-02-24 | 1992-08-25 | The British Petroleum Company P.L.C. | Method for manufacturing composite material |
| US5252279A (en) * | 1991-01-17 | 1993-10-12 | Reinhold Industries | Method for making perforated articles |
| US8602156B2 (en) | 2006-05-19 | 2013-12-10 | United Technologies Corporation | Multi-splice acoustic liner |
| JP2007309326A (en) * | 2006-05-19 | 2007-11-29 | United Technol Corp <Utc> | Liner assembly for aircraft engine housing and method for attenuating noise in aircraft engine housing |
| EP1857656A3 (en) * | 2006-05-19 | 2009-04-01 | United Technologies Corporation | Multi-splice acoustic liner |
| US9061769B2 (en) | 2010-12-09 | 2015-06-23 | Airbus Operations S.A.S. | Air inlet for aircraft propulsion unit having a structure resistant to excess pressure and a process for repairing an air inlet of an aircraft propulsion unit |
| FR2968636A1 (en) * | 2010-12-09 | 2012-06-15 | Airbus Operations Sas | AIR INTAKE FOR AIRCRAFT PROPULSIVE ASSEMBLY HAVING A SURPRISING RESISTANT STRUCTURE AND METHOD FOR REPAIRING AN AIRCRAFT PROPULSIVE ASSEMBLY AIR INTAKE |
| EP2463197A1 (en) * | 2010-12-09 | 2012-06-13 | Airbus Operations (Société par actions simplifiée) | Air intake for propulsion system of an aircraft with a structure withstanding overpressure and method for repairing an air intake of an aircraft propulsion system |
| WO2013007937A3 (en) * | 2011-07-13 | 2013-03-28 | Snecma | Method for manufacturing a turbine-engine fan casing having an acoustic coating |
| GB2506321A (en) * | 2011-07-13 | 2014-03-26 | Snecma | Method for manufacturing a turbine-engine fan casing having an acoustic coating |
| US9316120B2 (en) | 2011-07-13 | 2016-04-19 | Snecma | Method for manufacturing a turbine-engine fan casing having an acoustic coating |
| GB2506321B (en) * | 2011-07-13 | 2016-08-17 | Snecma | Method for manufacturing a turbine-engine fan casing having an acoustic coating |
| CN109606708A (en) * | 2018-12-03 | 2019-04-12 | 江西洪都航空工业集团有限责任公司 | A kind of small size inlet structure preparation method |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| WAP | Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1) |