GB2065016A - Moulding reinforced resin articles - Google Patents

Moulding reinforced resin articles Download PDF

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Publication number
GB2065016A
GB2065016A GB7942158A GB7942158A GB2065016A GB 2065016 A GB2065016 A GB 2065016A GB 7942158 A GB7942158 A GB 7942158A GB 7942158 A GB7942158 A GB 7942158A GB 2065016 A GB2065016 A GB 2065016A
Authority
GB
United Kingdom
Prior art keywords
resin
thermo
plastic resin
fibre
blade
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.)
Granted
Application number
GB7942158A
Other versions
GB2065016B (en
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Rolls Royce PLC
Original Assignee
Rolls Royce PLC
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Rolls Royce PLC filed Critical Rolls Royce PLC
Priority to GB7942158A priority Critical patent/GB2065016B/en
Publication of GB2065016A publication Critical patent/GB2065016A/en
Application granted granted Critical
Publication of GB2065016B publication Critical patent/GB2065016B/en
Expired legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00—Subject matter not provided for in other groups of this subclass
    • B29D99/0025—Producing blades or the like, e.g. blades for turbines, propellers, or wings
    • 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
    • B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
    • B29C70/443—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding and impregnating by vacuum or injection
    • 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
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • 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
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/86—Incorporated in coherent impregnated reinforcing layers, e.g. by winding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B64—AIRCRAFT; AVIATION; COSMONAUTICS
    • B64C—AEROPLANES; HELICOPTERS
    • B64C11/00—Propellers, e.g. of ducted type; Features common to propellers and rotors for rotorcraft
    • B64C11/16—Blades
    • B64C11/20—Constructional features
    • B64C11/26—Fabricated blades
    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/10—Isostatic pressing, i.e. using non-rigid pressure-exerting members against rigid parts or dies
    • B29C43/12—Isostatic pressing, i.e. using non-rigid pressure-exerting members against rigid parts or dies using bags surrounding the moulding material or using membranes contacting the moulding material

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Aviation & Aerospace Engineering (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)

Abstract

A method of making a fibre reinforced composite fan blade including at least one insert comprises laying upon a former a plurality of fibres impregnated with thermo-plastic resin, pressing the structure to finished size, inserting the inserts within the structure and subsequently injecting the structure with thermo-setting resin to fill the remaining voids within the structure.

Description

SPECIFICATION Improvements in or relating to composite structures This invention relates to fibre reinforced composite structures, and particularly to making such structures which include inserts.
Due to their relative high strength and light weight characteristics, fibre reinforced composite materials have been used increasingly in the manufacture of parts for gas turbine engines in recent years.
Whilst such structures are more commonly used in the manufacture of static components for example casings etc., some use has also been made in the manufacture of rotating components such as for example fan blades and compressor blades. Such blades are more usually fabricated from resin impregnated fibre sheets which are stacked together to form the appropriate blade shape before being subjected to both heat and pressure within a mould such that the material is pressed to its finished size.
In the case of fan blades it has also been necessary to provide additional reinforcement within the aerofoil section of the blade. The reinforcement consisting of a plurality of metal pins which are arranged translaminaely within the blade together with an edge reinforcement which is applied to the leading edge of the blade.
It has been found that when manufacturing composite materials including inserts such as for example the aforementioned pins, the pins tend to be displaced from their preferred locations during the moulding process. The main reasons for this is that inserts are not always driven into the composite in the moulding direction, and they are also displaced by the resin flow within the mould.
An object of the present invention is to provide a manufacturing method wherein the aforementioned disadvantage is substantially eliminated.
A method of making a fibre reinforced composite structure including at least one insert comprises laying up upon a former a plurality of fibres, each having a coating of thermo-plastic resin or alternatively each being coated with thermo-plastic resin either during or after laying up, softening the resin, pressing the structure upon the former to finished size and placing at least one insert within its preferred location within the composite structure, rigidifying the thermo-plastic resin and subsequently injecting the structure with thermo-setting resin to fill the remaining voids within the structure.
Preferably the thermo-plastic resin forms between 4 and 15% of the total resin content of the structure.
Furthermore the thermo-plastic resin is softened within the former after laying up the fibres by heating, or alternatively a solvent may be applied during the laying up process or afterwards which is subsequently evaporated from the structure to rigidify it.
Preferably the thermo-plastic resin comprises polysulphone, and the fibre comprises carbon or glass fibre, preferably in the form of thermo-plastic resin impregnated tows or sheets.
A method of making a gas turbine engine fan blade including at least one insert comprises laying upon a former a plurality of fibres each having a coating of thermo-plastic resin, softening the resin and consolidating the structure upon the former to finished size, inserting the at least one insert within the consolidated structure, rigidifying the resin and subsequently injecting the structure with thermosetting resin to fill the remaining voids within the structure.
Preferably the at least one insert comprises a plurality of reinforcement pins secured within the blade, and a leading edge reinforcement secured to the leading edge of the blade.
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 portion of a gas turbine engine including fan blades made in accordance with an embodiment of the present invention, Figure 2 shows an enlarged view in greater detail of one of the fan blades shown at Figure 1.
Referring to the drawings, a gas turbine engine, a portion of which is shown generally at 10 comprises a front fan 12 situated within a fan cowl 13, the fan 12 consisting of a plurality of fan blades 14 one of which is shown in greater detail at Figure 2.
A method of making such a blade consists of laying up a plurality of-carbon fibres upon a former which conforms substantially to a portion of the finished shape of the blade. To simplify manufacture it is most convenient to lay up the fibres in the form of pre-shaped sheets which are impregnated with the necessary thermo-plastic polysulphone resin.
However the fibres could be laid-up in the form of tows or single fibres which are coated with the necessary thermo-plastic resin. However this method would be both time consuming and tedious.
According to a further aspect of the present invention resin free laminations may be laid upon the former and then be coated with a solution of polysulphone resin.
After laying up, the laminates are heated in the mould and pressure is applied to effect the forming of the composite to the finished dimensions and create local bridges of the thermo-plastic between the fibres.
Alternatively a known amount of a solvent such as for example methylene chloride may be disposed into each laminate during laying-up in the die and the wet stack is then pressed to the required dimensions.
After forming the composite upon the former the necessary inserts in the form of reinforcement pins some of which are shown generally at 15 may be inserted into the structure. The reinforcement pins 15 are inserted into the composite whilst the thermoplastic resin is still hot in the mould. Alternatively they may be inserted prior to driving the solvent from the mould. After rigidifying the composite structure it is removed from the former and the leading edge reinforcement is located upon the blade. Because the blade is at a finished size this is a simple operation.
After insertion of the inserts comprising both the pins and leading edge reinforcement and any other required inserts the preformed structure is enclosed with a die which is subsequently evacuated priorto being injected with thermo-setting resin, which resin is subsequently cured to complete the composite fan blade.
It will be appreciated that whilst the particularly described embodiment of the present invention relates to the manufacture of gas turbine engine fan blades. The invention is no way restricted to the manufacture of such components as the invention could equally well be applied to the manufacture of a wide range of articles requiring the advantage of high strength and light weight allowed by the use of fibre reinforced composites and requiring accurately located inserts within the structure. Furthermore it is not intended that this invention be restricted only to the use of glass or carbon fibres as any other suitable high strength fibre could be used for example metallic fibres.

Claims (8)

1. A method of making fibre reinforced composite structure including at least one insert comprises laying up on a former a plurality of fibres each having a coating of thermo-plastic resin, or alternatively each fibre being coated with thermo-plastic resin during or after lay-up, softening the resin, pressing the structure to finished size and placing at least one insert within its preferred location within the composite structure, regidifying the thermoplastic resin, and subsequently injecting the structure with thermo-setting resin to fill the remaining voids within the structure.
2. A method as claimed in claim 1 in which the thermo-plastic resin forms between 4 and 15% of the total resin content of the structure.
3. A method as claimed in claims 1 and 2 in which the thermo-plastic resin is softened by heating, or alternatively a solvent may be applied during the laying up process or afterwards which is subsequently evaporated from the structure to rigidify it.
4. A method as claimed in claims 1,2 and 3 in which the thermo-plastic resin comprises polysulphone.
5. A method as claimed in any preceding claim in which the fibre comprises, carbon, or a glas fibre, preferably in the form of thermo-plastic resin inpregnated tows or sheets.
6. A method of making a gas turbine engine fan blade including at least one insert comprises laying upon a former a plurality of fibres each having a coating of thermo-plastic resin, softening the resin, consolidating the structure, rigidifying the resin, and subsequently injecting the structure with thermosetting resin to the remaining voids within the structure.
7. A method as claimed in claim 6 in which the at least one insert comprises a plurality of reinforcement pins secured within a blade, and a leading edge reinforcement secured to the leading edge of the blade.
8. A gas turbine engine fan blade made by the method claimed in any preceding claim substantially as hereinbefore described by way of example only and as illustrated in the accompanying drawings.
GB7942158A 1979-12-06 1979-12-06 Moulding reinforced resin articles Expired GB2065016B (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB7942158A GB2065016B (en) 1979-12-06 1979-12-06 Moulding reinforced resin articles

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB7942158A GB2065016B (en) 1979-12-06 1979-12-06 Moulding reinforced resin articles

Publications (2)

Publication Number Publication Date
GB2065016A true GB2065016A (en) 1981-06-24
GB2065016B GB2065016B (en) 1983-02-23

Family

ID=10509665

Family Applications (1)

Application Number Title Priority Date Filing Date
GB7942158A Expired GB2065016B (en) 1979-12-06 1979-12-06 Moulding reinforced resin articles

Country Status (1)

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GB (1) GB2065016B (en)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4515743A (en) * 1982-01-04 1985-05-07 Breco Kunststoffverarbeitungs- Gmbh & Co. Kg Method of producing a reinforced toothed belt having a fabric cover
DE3523517A1 (en) * 1984-07-07 1986-02-06 Rolls Royce SHOVEL BODY AND METHOD FOR PRODUCING SUCH A
DE3523518A1 (en) * 1984-07-07 1986-02-06 Rolls-Royce Ltd., London RING SHAPED BUCKET BODY WITH AN INTEGRAL BUCKET RING AND METHOD FOR PRODUCING THE SAME
US4690860A (en) * 1984-01-06 1987-09-01 The Wiggins Teape Group Limited Fibre reinforced composite plastics material
US4882114A (en) * 1984-01-06 1989-11-21 The Wiggins Teape Group Limited Molding of fiber reinforced plastic articles
US4925615A (en) * 1985-11-01 1990-05-15 The Wiggins Teape Group Limited Method of molding fiber reinforced plastic articles

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB8618726D0 (en) 1986-07-31 1986-09-10 Wiggins Teape Group Ltd Thermoplastics material
US5242749A (en) 1987-03-13 1993-09-07 The Wiggins Teape Group Limited Fibre reinforced plastics structures
GB8818425D0 (en) 1988-08-03 1988-09-07 Wiggins Teape Group Ltd Plastics material
CN104385619B (en) * 2014-09-09 2017-07-04 西安航空动力股份有限公司 A kind of manufacture method of aero-engine composite material fan blade

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4515743A (en) * 1982-01-04 1985-05-07 Breco Kunststoffverarbeitungs- Gmbh & Co. Kg Method of producing a reinforced toothed belt having a fabric cover
US4690860A (en) * 1984-01-06 1987-09-01 The Wiggins Teape Group Limited Fibre reinforced composite plastics material
US4882114A (en) * 1984-01-06 1989-11-21 The Wiggins Teape Group Limited Molding of fiber reinforced plastic articles
DE3523517A1 (en) * 1984-07-07 1986-02-06 Rolls Royce SHOVEL BODY AND METHOD FOR PRODUCING SUCH A
DE3523518A1 (en) * 1984-07-07 1986-02-06 Rolls-Royce Ltd., London RING SHAPED BUCKET BODY WITH AN INTEGRAL BUCKET RING AND METHOD FOR PRODUCING THE SAME
US4925615A (en) * 1985-11-01 1990-05-15 The Wiggins Teape Group Limited Method of molding fiber reinforced plastic articles

Also Published As

Publication number Publication date
GB2065016B (en) 1983-02-23

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PCNP Patent ceased through non-payment of renewal fee