JP2984805B2 - Method of manufacturing three-dimensional fiber structure integrated with blade / shaft cylinder - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an airfoil structure for an aircraft turbine or other axial compressor, which is made of FRP, FRM, carbon / carbon or ceramic / ceramic composite material reinforced with a three-dimensional woven fiber structure. method for producing a three-dimensional fiber structure of the blade / shaft tube integrated to configure it relates.

[0002]

2. Description of the Related Art Conventionally, airfoil structures such as aircraft turbines have been manufactured from titanium or other metal materials. However, the weight of the structure is increased, the number of processing steps is increased, and the cost is increased. There was a problem.

[0003] Therefore, some attempts have been made to reduce the weight by replacing an airfoil structure such as an aircraft turbine with a composite material such as carbon / epoxy resin from titanium or other metal materials. For example, JP-A-63-2955741, U.S. Pat.
No. 460, JP-A-2-144297 and the like have been proposed.

[0004]

SUMMARY OF THE INVENTION Japanese Patent Application Laid-Open No. 63-2957
According to the proposal of JP-A-41, a cylindrical structure can be manufactured from a composite material, but the wing portion cannot be integrally formed. Therefore, in the case of this proposal, the wing part and the barrel part must be joined later by some means.

In the proposal of US Pat. No. 3,632,460, the wing portion and the barrel portion can be integrally formed by a composite material, but a one-dimensional structure is proposed for the orientation of fibers. There is no entanglement between fibers.

[0006] Japanese Patent Application Laid-Open No. 2-144297 proposes
The wing part and the barrel part are manufactured separately from each other by using a composite material, and are assembled using joining pins. The wing part and the barrel part can be integrally formed with the composite material. is not.

[0007] The proposals of JP-A-63-295574 and JP-A-2-144297 mentioned above require that the wing portion and the shaft cylinder portion be joined later, so that the strength of these joints is improved. However, even if the strength can be satisfied, there are problems such as an increase in weight, a deterioration in start-up performance (acceleration performance) up to a predetermined number of revolutions, and a shift response.

In addition, the above-mentioned US Pat. No. 3,632,460
The proposal of the specification describes that the orientation of the fibers is a one-dimensional structure, and there is no entanglement between the fibers in each part, so that external forces in each direction such as thrust, centrifugal force, torsion force, etc. acting on the wing, impact and vibration It is difficult to improve strength.

Conventionally, it has been proposed to manufacture an airfoil structure for an aircraft turbine or the like from a three-dimensional fiber structure made of a composite material. Since it is manufactured and then cut to make an airfoil structure, in the case of an airfoil structure with a complicated shape, the cutting process itself is difficult, or if the cutting process was possible However, there is a problem that the fiber is cut everywhere and the strength of the three-dimensional fiber structure cannot be sufficiently exerted against external force such as impact or vibration.

[0010] The present invention provides a blade / shaft tube in which the strength of the joint is improved by integrally forming the wing portion and the shaft tube portion without forming a cut end of the thread in the wing portion. and its object is to provide a method for producing a three-dimensional fiber structure type.

[0011]

[0012]

[0013]

[0014]

Means for Solving the Problems To achieve the above object,
Therefore, the method for manufacturing a three-dimensional fiber structure integrally with a wing / shaft tube of the present invention comprises forming the woven portion of the shaft tube portion in a state where the shaft tube portion is expanded, and forming the woven portion of the wing portion. A plurality of thread guide tubes are formed in parallel at a predetermined pitch along the Z direction of the woven portion and the woven portion of the wing portion in a series at a predetermined pitch and angle on one side of the shaft tube portion. And the yarn in the X direction and Y
The yarns in the Z direction are stacked and arranged in a continuous state to fill the insides of both the weaving sections. Thereafter, the yarns in the Z direction are replaced and arranged in the both weaving sections with the yarn guide tubes to fill the yarns. The invention is characterized in that both ends of the shaft cylinder portion are joined with a thread to form an annular shaft cylinder portion.

Further, in the method of manufacturing a three-dimensional fiber structure integrally with a blade / axial cylinder according to the present invention, the oblique yarns intersecting in both directions are arranged in a plane in which the yarns in the X direction and the yarns in the Y direction are arranged. It is characterized by being arranged and woven.

Further, in the method for manufacturing a three-dimensional fiber structure integrally with a blade / shaft tube according to the present invention, a plurality of joint yarn guide tubes are arranged in the weaving portions at both developed end portions of the shaft tube portion. One end of one of the guide pipes for the joining yarn has a small diameter end, and at the time of joining the shaft tube portion, the joining tube guides for the joining yarns at both the developed end portions of the shaft tube portion are joined at the small diameter end to form a joining yarn. It is characterized by being arranged to be replaced.

[0017]

The three-dimensional fiber structure integrated with the wing / axial cylinder manufactured according to the present invention exhibits the expected strength due to the oriented yarns in which the fibers are not cut. Moreover, since the thread of the wing is continuous with the thread of the barrel, the strength at the joint between the wing and the barrel is improved.

Further, according to the method of manufacturing a three-dimensional fiber structure integrated with a blade / shaft tube of the present invention, the shaft tube portion is woven in a developed state, and both ends of the shaft tube portion in a developed state are joined by a thread. By forming an annular shape, the X-direction yarn and the Y-direction yarn are arranged in both directions in order to obtain strength against external force in each direction such as thrust, centrifugal force, and torsional force acting on the wing. It is possible to weave a wing part without a thread cut end in a complicated shape in which oblique threads intersecting with the shaft cylinder part are integrated. Furthermore, in the weaving portion at both ends of the deployed shaft cylinder portion, a plurality of joining yarn guide tubes are arranged, and one end of one of the joining thread guide tubes has a small diameter end. By joining the guide threads for the joining yarns at the two ends of the shaft cylinder portion at the small-diameter ends to replace the joining thread, the joining of the shaft cylinder portions becomes easy.

[0019]

1 (A) and 1 (B) show the fiber orientation of the wing portion manufactured by the present invention, (C) shows the fiber orientation of the barrel portion, and (D) FIG. 1 is a schematic perspective view showing an example of a developed state of a three-dimensional fiber structure integrated with a wing / shaft tube manufactured by the present invention;
(E) is a schematic perspective view of the final shape of the three-dimensional wing / shaft-cylinder integrated fiber structure manufactured by the present invention shown in (D). In these figures, (1) is a yarn in the X direction, (2) is a yarn in the Y direction, (3) is a yarn in the V direction,
(4) shows a yarn in the W direction, and (5) shows a yarn guide tube. The yarn (3) in the V direction and the yarn (4) in the W direction are X
The oblique yarns are arranged in the arrangement plane of the yarns (1) in the Y direction and the yarns (2) in the Y direction so as to intersect with both directions. In FIG. Although the case of an angle is illustrated, the present invention is not limited to this, and another intersection angle may be used.

The three-dimensional wing / shaft-cylinder integrated three-dimensional fiber structure (10) manufactured by the present invention is, as shown in FIG.
A shaft cylinder (6) and a wing (7) integrally formed at a predetermined pitch and angle around the outside of the shaft cylinder (6). As shown in FIG. 1D, the three-dimensional fiber structure (10) integrated with the wing / shaft tube manufactured by the present invention is developed by expanding the shaft tube portion (6). Weaving is performed in a state where the wing portion (7) is integrally formed with the portion (6), and after weaving, both ends (6a) and (6b) of the shaft tube portion (6) are joined by joining yarn to form an annular shape. . In this weaving, at least one or both of the barrel portion (6) and the wing portion (7) are woven with a three-dimensionally oriented yarn, and a part of the yarn of the wing portion (7) or The whole is woven continuously with the shaft cylinder (6).
That is, as illustrated in FIG. 1 (C), the shaft tube portion (6) is provided with the yarn (1) in the X direction and the yarn (1) in the Y direction arranged at a predetermined pitch. The yarns (2) are stacked and arranged in a continuous state, and the yarns in the Z direction are not shown, but are arranged in place of the yarn guide tubes (5). If necessary, oblique arrangement is also performed. The wings (7) are shown in FIGS.
As shown in the figure, a yarn (1) in the X direction, a yarn (2) in the Y direction, V
Directional yarn (3) and W-directional yarn (4) are laminated and arranged in a predetermined order and the number of laminations in a continuous state, respectively.
The yarns in the direction are not shown, but are arranged in place of the yarn guide tubes (5).

In FIGS. 1A, 1B and 1C, a part of the yarn of the wing portion (7), that is, the yarn (1) and the Y in the X direction.
Although the case where the yarn (2) in the direction is continuously woven with the shaft cylinder portion (6) is illustrated, the yarn (3) in the V direction and the yarn (4) in the W direction are also continuously woven. It may be woven. Further, the slanted yarns may be arranged in combination with yarns in other directions in addition to yarns (3) in the V direction and yarns (4) in the W direction.

The three-dimensional fiber structure (1)
In the manufacturing method 0), as shown in FIGS. 2A and 2B, the shaft cylinder portion (6) is set in an expanded state, and the wing portion (7) is integrally formed at one side with a predetermined pitch and angle. After weaving, both ends (6a) and (6b) of the shaft cylinder portion (6) in a deployed state are joined to form an annular shape. In this case, the shaft cylinder portion (6) in the expanded state
The two ends (6a) and (6b) are engaged with each other.
Are formed and these are engaged to prevent an extreme change in the thickness and strength of the joint. The cross-sectional shape of the wing portion (7) may be a crescent shape, an aircraft wing shape (Aero-foil), or the like as shown in FIGS.

FIGS. 3A and 3B are a side view and a front view, respectively, showing a specific example of a method of manufacturing the above-mentioned three-dimensional fiber structure (10) integrated with the blade / shaft cylinder. The woven part (8) of the barrel part (6) is formed in a state where the barrel part (6) is developed, and the woven part (9) of the wing part (7) is formed in the barrel part (6). ) Is formed in a series at a predetermined pitch and angle on one side,
A thread guide tube (5) is erected on the weaving portions (8) and (9) via a base plate (11) along the Z direction at a pitch according to the characteristics required for the shape of the final molded product. A spacer (12) having a predetermined shape is installed between the yarn guide tubes (5) between the weaving portions (9) of the wing portion (7), and the both weaving portions (8) and (9) are installed. The X-direction yarn (1), the Y-direction yarn (2), the V-direction yarn (3), and the W-direction yarn (4) are stacked and arranged in a predetermined order and the number of layers. To fill both weaving sections (8) and (9).

The arrangement of the yarn in each direction with respect to the yarn guide tube (5) is arranged in the manner illustrated in FIGS. 1A, 1B and 1C.

Part of the start of lamination and part of the end of lamination, ie,
At both ends (6a) and (6b) of the shaft cylinder portion (6) in the unfolded state, the stacking arrangement of the threads is reduced to form the engaging step portions (6c) and (6d). The yarns are laminated while inserting the guide tubes (13) and (14) for the joint yarns into the yarns.

FIG. 3 shows an example in which the yarn guide tube (5) is arranged in the vertical direction. However, the base plate (11) is adapted to the shape (curved surface shape, etc.) of the wing (7). May be planted at a predetermined inclination angle (for example, 15 ° to 30 °).

As described above, the yarn (1) in the X direction
When the lamination of the Y-direction yarn (2), the V-direction yarn (3) and the W-direction yarn (4) is completed, the Z-direction yarn (not shown) is connected to the yarn guide tube (5). Replace and place. This replacement arrangement is performed, for example, by extracting the yarn guide tube (5) and thereafter inserting the Z-direction yarn.
The yarns in the Z direction are preferably arranged continuously at both ends or one end of the shaft cylinder portion (6) in the unfolded state. Also,
In the wing part (7), the yarn in the Z direction is made continuous and arranged so as not to generate a cut end.

When the arrangement of the yarns in the Z direction is completed in this way, the shaft cylinder (6) is bent and both ends (6a) are bent.
The engaging step portions (6c) and (6d) of (6b) are engaged. In this case, one end of the joining yarn guide tubes (13) (14) is
As shown in (C), when the engagement step portions (6c) and (6d) are engaged, the other joining yarn guide tube (1) is used as the small-diameter end (14a).
3), and in this state, while pulling out both the guide pipes (13) and (14) for the joint yarn, the joint yarn (not shown)
To form an annular barrel portion (6) in which the wing portions (7) are integrated.

The three-dimensional wing / shaft-cylinder integrated three-dimensional fiber structure (10) formed as described above is then coated with a resin matrix or an inorganic matrix such as carbon or silicon carbide having excellent high-temperature characteristics by a known method. To form a composite wing. In addition, various fibers having heat resistance such as carbon fiber, glass fiber, ceramics fiber, and aramid fiber can be used as the constituent fiber of the yarn used in the present invention. It may be in any form such as a thread. In the above-described embodiment, the case where the yarn guide tubes (5) are arranged along the developing direction of the shaft tube portion (6) is exemplified, but the present invention is not limited to this.

[0030]

According to the present invention , the three-dimensional wing / shaft-cylinder integrated three-dimensional fiber structure produced according to the present invention has the expected strength due to the oriented yarns in which the fibers are not cut. Moreover, since the thread of the wing is continuous with the thread of the barrel, the strength at the joint between the wing and the barrel is improved.

Further, in the method for manufacturing a three-dimensional fiber structure integrally with a blade / shaft tube according to the present invention, the shaft tube portion is woven in a developed state and both ends of the shaft tube portion in a developed state are joined by a thread. By forming an annular shape, the X-direction yarn and the Y-direction yarn are arranged in both directions in order to obtain strength against external force in each direction such as thrust, centrifugal force, and torsional force acting on the wing. It is possible to weave a wing part without a thread cut end in a complicated shape in which oblique threads intersecting with the shaft cylinder part are integrated. Furthermore, in the weaving portion at both ends of the deployed shaft cylinder portion, a plurality of joining yarn guide tubes are arranged, and one end of one of the joining thread guide tubes has a small diameter end. By joining the guide threads for the joining yarns at the two ends of the shaft cylinder portion at the small-diameter ends to replace the joining thread, the joining of the shaft cylinder portions becomes easy.

Further, the manufacturing method of the present invention is for manufacturing by solidifying together with a matrix resin in a mold a three-dimensional fiber structure in which the wing portion and the shaft cylinder portion of the final shape are integrally woven with continuous yarn. The number of processing steps is small and the cost can be reduced.

In addition, various inclination angles of the wing portion with respect to the shaft cylinder portion can be manufactured, and therefore, a simple curved wing shape to a complicated curved wing shape can be easily manufactured.

Further, the three-dimensional fiber structure integrated with the wing / screw cylinder manufactured by the present invention is lighter in weight, faster to a predetermined number of revolutions, and accelerated than a conventional metal material such as titanium. Performance and shift response are improved. In addition, the specific strength is large, the number of rotations can be increased, and a high output can be obtained.

[Brief description of the drawings]

1 (A) and 1 (B) show the fiber orientation of a wing manufactured in the present invention , FIG. 1 (C) shows the fiber orientation of a shaft cylinder,
(D) is a schematic perspective view showing an example of a developed state of the three-dimensional fiber structure integrated with the blade / axial cylinder manufactured in the present invention , and (E).
1 is a schematic perspective view of the final shape of the three-dimensional wing / shaft-cylinder integrated fiber structure manufactured by the present invention shown in (D).

FIG. 2A is a schematic perspective view showing another example of a developed state of the three-dimensional fiber structure of the blade / axial cylinder integrated type manufactured by the present invention , and FIG. FIGS. 3C and 3D are schematic cross-sectional views showing examples of a cross-sectional shape of a wing portion of a three-dimensional fiber structure of an integral wing / screw tube manufactured by the present invention.

3 (A) and 3 (B) are a side view and a front view of a fiber structure laminated by the production method of the present invention, and FIG. 3 (C) is a perspective view for explaining a joining yarn guide tube.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 X direction thread 2 Y direction thread 3 V direction thread 4 W direction thread 5 Thread guide tube 6 Shaft tube part 7 Wing part 8 Woven part of shaft tube part 9 Weaving of wing part Part 10 Wing / shaft tube integrated three-dimensional fiber structure 13 Joint yarn guide tube 14 Joint yarn guide tube

──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Shigeru Nishiyama 10 Nagoya-shi, Aichi Prefecture Oe-cho, Minato-ku Mitsubishi Heavy Industries, Ltd. -4 (72) Inventor Masayasu Ishibashi 297 Kenbu-Kitamachi, Yoka City, Shiga Prefecture (56) References JP-A-3-78503 (JP, A) JP-A-1-207465 (JP, A) JP-A-62-268846 ( JP, A) JP-A-2-241901 (JP, A) (58) Fields investigated (Int. Cl. ⁶ , DB name) F01D 5/28 D04H 3/00 F01D 5/14

Claims (3)

(57) [Claims] The woven portion of the barrel portion is formed in a state where the barrel portion is developed, and the woven portion of the wing portion is formed on one side of the barrel portion at a predetermined pitch and angle. A plurality of yarn guide tubes are arranged in parallel at a predetermined pitch along the Z direction of the shaft tube woven portion and the wing portion woven portion, and the X direction yarn and the Y direction yarn are arranged therebetween. The two weaving sections are filled in a continuous state so that the inside of the both weaving sections is filled. Thereafter, the yarns in the Z direction are replaced with the thread guide tubes in the both weaving sections to be filled, and finally, the shaft cylinder section is developed. A method for manufacturing a three-dimensional fiber structure integrally with a blade / shaft tube, wherein both end portions are joined by a thread to form an annular shaft tube portion. 2. The wing / shaft according to claim 1, wherein oblique yarns intersecting in both directions are arranged and woven in a plane in which the X-direction yarns and the Y-direction yarns are arranged. A method for manufacturing a three-dimensional fiber structure integrated with a cylinder. 3. A plurality of joint yarn guide tubes are disposed in the weaving portions at both ends of the shaft tube portion, and one end of one of the joint yarn guide tubes has a small diameter end. 3. The joining yarn guide tubes at both ends of the shaft cylinder portion are joined at the small-diameter end at the time of joining, and are replaced with the joining yarn. A method for producing a three-dimensional fiber structure integrated with a wing / shaft cylinder.