JPH04308251A - Rotating blade utilizing three-dimensional woven fabric and production thereof - Google Patents

Abstract

PURPOSE:To eliminate problem of release of laminate material and simultaneously make a woven fabric lightweight moreover by making orientation of reinforced fiber reasonable. CONSTITUTION:In a three-dimensional woven fabric having cross section necessary as rotation blade, yarn 2a oriented in a state inclined in longitudinal direction of three-dimensional woven fabric in vertical face and yarn 2b similarly inclined in horizontal face are provided and these yarns are folded on the surface of woven fabric and mutually woven as fabric continuing in the longitudinal direction and core yarn linearly oriented in the longitudinal direction of three- dimensional woven fabric is woven in whole or part of cross section of the woven fabric.

Description

[Detailed description of the invention]

0001

[Field of Industrial Application] The present invention relates to a rotary blade using a three-dimensional fabric as a reinforcing material and a method for manufacturing the same. The present invention relates to a rotating blade, such as a blade or an aircraft propeller blade, which receives centrifugal force and composite force as it rotates, and a method for manufacturing the same.

0002

BACKGROUND OF THE INVENTION Fiber-reinforced composite materials have been used for various types of rotary blades, including blades for helicopters, ATPs, and aircraft, to extend their usable life and further reduce their weight. Generally speaking, these rotating blades are made by laminating carbon/aramid or glass fiber cloth and bonding them together using a matrix, or by using these reinforcing fibers and molding them using a filament winding method, which increases strength. Measures such as adjusting the thickness are being considered in order to make it last longer.

However, when cloth-like materials made of reinforcing fibers are laminated, there is a problem of delamination between the layers, which limits the use of the material, and especially when complex materials such as centrifugal force and compound force of rotating blades etc. For members to which force acts, sufficient consideration must be given to the strength corresponding to the stress generated in each part, and it may not be possible to achieve a satisfactory weight reduction. Therefore, there is a desire to develop a rotating blade that does not suffer from the above-mentioned problems such as peeling and which has increased strength in any direction using reinforcing fibers.

0004

[Problems to be Solved by the Invention] The technical problem of the present invention is to provide a rotary blade that solves the problem of peeling of laminated materials by optimizing the orientation of reinforcing fibers, and at the same time achieves further weight reduction. The purpose is to obtain a manufacturing method.

[0005]

[Means for Solving the Problems] A rotating blade of the present invention for solving the above-mentioned problems is made of a three-dimensional fabric having a cross-sectional shape necessary for a rotating blade. , yarns oriented at an appropriate angle with respect to the length direction of the three-dimensional fabric, and a large number of yarns oriented at an appropriate angle with respect to the length direction of the three-dimensional fabric in the horizontal plane, or , a large number of yarns that are inclined at an appropriate angle with respect to the length direction of the three-dimensional fabric in the vertical plane and at an appropriate angle with respect to the length direction of the three-dimensional fabric in the horizontal plane are each arranged on the fabric surface. By folding back, weaving is continuous in the length direction, and the entire or part of the cross section of the fabric is
It is characterized by weaving core threads oriented linearly in the length direction of the three-dimensional fabric.

[0006] Furthermore, in the method for manufacturing a rotating blade of the present invention, a large number of rotors sandwiching yarn carriers between adjacent rotors are arranged adjacent to each other in a large number of rows and a large number of columns, and the four circumferences of each adjacent rotor are A yarn carrier corresponding to the weaving shape of the three-dimensional fabric is sandwiched between the two, and when one adjacent rotor rotates, the yarn carrier is moved using the concave portion of the other rotor as a guide, and this is repeated to rotate. When weaving the three-dimensional fabric constituting the blade, the above-mentioned yarn carriers are arranged to match the cross-sectional shape of the rotating blade, and cores are inserted in the longitudinal direction of the three-dimensional fabric from the center of the necessary rotor in the arrangement. Then, out of the many rotors, the rotors that are not adjacent to each other in the above rows and columns are classified as one group, and the whole is divided into two groups, and the rotors of one group are used as non-rotating fixed guides to guide the other rotors. The group is rotated 90° or 180° in one direction, and then the other groups are rotated 90° or 180° in the opposite direction to the above, using the rotor of the first group as a fixed guide, and this is done sequentially. By repeating the process, the threads are woven mutually in an inclined state with respect to the length direction of the three-dimensional fabric, and the threads are oriented in a direction that increases the strength using a rotating blade. be.

[0007]

[Function] The rotating blade having the above configuration has a large number of threads inclined at appropriate angles in the vertical plane and in the horizontal plane in a three-dimensional fabric having the necessary cross-sectional shape as a rotating blade. The orientation direction of the strips can be easily changed, and since the three-dimensional fabric has a core thread linearly oriented in the length direction, the three-dimensional fabric can be configured as a five-axis fabric, and can be used as a rotating blade. , it can exhibit strength against stress acting in various directions. That is, by optimizing the orientation of the reinforcing fibers, it is possible to solve the problem of peeling of the laminated material, and at the same time, it is possible to obtain a rotary blade and a method for manufacturing the same that can achieve further weight reduction.

[0008]

DESCRIPTION OF THE PREFERRED EMBODIMENTS FIGS. 1A to 1C and FIG. 2 show an example of the structure of a three-dimensional fabric constituting the rotating blade of the present invention. This three-dimensional fabric is shown as a beam-shaped one with a T-shaped cross section to explain the orientation state of the reinforcing fibers, but these are woven into various rotating blade shapes as described later with reference to FIGS. 10 to 12. When used, the reinforcing fibers are bonded together by the matrix.

[0009] The T-shaped beam member 1 constituting the three-dimensional fabric includes a vertical member 1a arranged vertically;
It is provided with a horizontal member 1b orthogonal to the vertical member 1a, and these are integrally woven. Both members 1a,
1b has a thickness equivalent to at least several layers of planar fabric, and both members 1a and 1b are integrally woven. Further, the horizontal member 1b is woven with core threads 3 linearly oriented in the length direction of the beam-shaped three-dimensional fabric. This core yarn 3 can be woven into the whole or part of the horizontal member 1b, thereby counteracting the centrifugal force when the three-dimensional fabric is rotated as a rotating blade.

FIGS. 1A to 2C and FIG. 2 show how the threads 2a, 2b and the core thread 3 are woven into the three-dimensional fabric, but for ease of understanding, some of the threads are Only the threads are shown as viewed from three mutually orthogonal directions and in a perspective view (the core yarn is omitted in FIG. 2). A large number of yarns 2a, 2a, . . . and 2b, 2b, . A three-dimensional fabric is thereby woven. Note that the circled numbers A and C in FIG. 1 and in FIG. 2 indicate corresponding positions.

The threads 2a in the beam-shaped member 1 constituting the three-dimensional fabric are oriented at an appropriate angle with respect to the length direction of the three-dimensional fabric in the vertical plane of the vertical member 1a and the horizontal member 1b. On the other hand, the threads 2b in the vertical member 1a and the horizontal member 1b are inclined to the longitudinal direction of the three-dimensional fabric within the horizontal plane, although the threads 2b are of the same degree as the threads 2a. These yarns 2a, 2b are continuous in the length direction of the beam by being folded back on the surface of the beam-shaped member 1, and a large number of them are woven together.

3A to 3C and FIG. 4 are for explaining the structure of a second embodiment of the three-dimensional fabric constituting the rotating blade of the present invention. In this embodiment, as in the case of the first embodiment, the beam-shaped member 11 constituting the three-dimensional fabric includes a vertical member 11a and a horizontal member 11b perpendicular to the vertical member 11a, and both members 11a, 11b has a thickness equivalent to at least several layers of planar fabric, and both members 11a and 11b are integrally woven. Also,
The horizontal member 11b is woven with a core yarn 13 linearly oriented in the length direction of a beam-shaped three-dimensional fabric. This core yarn 13 is connected to the horizontal member 1 as in the first embodiment.
It can be woven into all or part of 1b.

A to C in FIG. 3 correspond to A to C in FIG. 1, and FIG. 4 corresponds to FIG. 2, and FIGS.
In this figure, only the weaving mode of a single thread 12 in a three-dimensional fabric is shown. The other threads constituting the three-dimensional fabric are woven in substantially the same manner as the illustrated threads, thereby weaving the three-dimensional fabric. Each yarn 12 in the beam-like member 11 in this second embodiment is
In the vertical member 11a and the horizontal member 11b, these threads 12 are inclined at an appropriate angle in a plane perpendicular to the length direction of the three-dimensional fabric, and are also oriented to be inclined to the same extent in a horizontal plane. By folding back on the surface of the beam-shaped member 11, the weaving is continued in the length direction of the beam.

In a rotating blade, stress is generated in various directions depending on its purpose and use. By tilting the fibers in a desired direction and orienting the threads as much as possible in the direction of action of the principal stress, each thread 2a, 2b, 12 is folded back on the fabric surface to make them continuous in the length direction of the beam. , each thread effectively acts to increase the strength of the beam-shaped composite material. Moreover, by weaving the core yarns 3 and 13 linearly oriented in the length direction into the whole or part of the three-dimensional fabric to create a five-axis fabric, the strength in the core yarn direction is increased, and the strength in the core yarn direction is increased. Expansion and contraction in is also restricted. Note that the yarns 2a, 2b, 1
The inclination angle 2 can be determined by adjusting the degree of beating and the winding speed of the woven fabric in weaving, which will be described later.
It can be easily adjusted.

FIG. 5 shows an example of the external appearance of a beam-shaped three-dimensional fabric 20 having the structure explained with reference to FIGS. 3A to 4C and FIG. 4, and formed into an I-shaped cross section. In this example, the core yarn 23 is woven at a low density into the horizontal members 22, 22 (which become blade-like by increasing the width of this part) connected to the top and bottom of the vertical member 21. It can also be woven into the density, and such configurations
Since the deformation of the upper and lower horizontal members 22, 22 is restrained by the core yarn 23, it is advantageous for use in areas where curvature is not desired.

Next, a method for weaving the beam-shaped three-dimensional fabric will be explained based on FIGS. 6 to 8. When weaving the above-mentioned beam-shaped three-dimensional fabric, Fig. 6
A weaving device as shown in is used. This weaving device is
A large number of carrier drive units 31 arranged along the carrier track surface give motion to the yarn carrier 32 supporting a bobbin (not shown) so that it travels along a required trajectory.
The yarn 33 unwound from these bobbins is woven.

The carrier drive unit 31 includes a rotor 34 as shown in FIG. This rotor 34 holds the yarn carrier 32 between adjacent rotors, and is provided with recesses 35 on its four circumferences for holding the yarn carrier 32, and the inner surfaces of these recesses 35 are connected to the adjacent rotors. Each rotor 34 is shaped like an arc centered around the rotation axis of the rotor, and when one of the adjacent rotors 34, 34 rotates, the recess 35 of the other rotor functions as a guide for the yarn carrier 32. They are closely adjacent to each other and arranged in a plurality of rows and columns in the movement area of the yarn carrier 32. In addition, a core yarn insertion hole 37 is provided in the rotation shaft 36 at the center of each rotor 34, and this insertion hole 3
7 through the core thread 2 to the part of the three-dimensional fabric that requires reinforcement.
8. The core thread 28 can also be led out from a bobbin or the like provided at the center of the rotor, for example. In addition, in FIG. 6, reference numeral 39 indicates a fixed guide enclosed around the movement area of the yarn carrier 32.

On the other hand, the yarn carrier 32 held between the rotors 34 has a holding part 40 formed by two cylindrical surfaces 41, 41 that fit into the recesses 35 of the adjacent pair of rotors 34, and A bobbin support shaft 42 is provided upright.

When the yarn carrier 32 is driven by a large number of drive units 31 equipped with the rotor 34,
As shown in FIG. 6, the yarn carriers 32 are arranged in a moving region so as to match the cross-sectional shape of the vertical member 26 and the horizontal members 27a, 27b of the beam-shaped three-dimensional fabric 25. During weaving, the rotors 34 that are not adjacent to each other in the rows and columns of the rotor arrangement are treated as one group, and the whole is divided into two groups, and the rotors of each group are driven simultaneously, so that a drive (not shown) necessary for that drive is required. Means are provided. In FIG. 8, two groups are distinguished and shown by rotors with hatched lines and rotors without hatched lines.

The drive means of both groups provide intermittent rotational drive of 90° or 180° in the same direction to the rotor 34 of each group, and drive the drive means of both groups to rotate at least in mutually opposite directions. It is considered possible. In the following explanation, the hatched rotor in FIG. 8 is referred to as a rotor (
The group of these rotors is hereinafter referred to as the first group. ), and the rotor without diagonal lines is a rotor that rotates intermittently by 90° or 180° counterclockwise (hereinafter, these rotor groups will be referred to as 2nd rotor).
It's called a group. ).

Weaving is carried out by using one group of rotors 34 as non-rotating fixed guides and rotating the other group at 90° or 18° in one direction.
This is done by rotating the rotors by 0°, then rotating the other groups by 90° or 180° in the opposite direction to the above using the previously rotated group of rotors as a fixed guide, and repeating this sequentially, In FIG. 8, the rotors of the first group and the second group are driven to rotate alternately.

Observing the movement of the yarn carriers during weaving, it is found that the yarn carriers move under relatively simple regularity within the array range of the yarn carriers in both cases of 90° and 180°. For example, when the rotors of the first group and the second group are rotated by 90 degrees in the forward and reverse directions using a rotor arrangement as shown in FIG. 6, it is possible to obtain a three-dimensional fabric 20 having an appearance as shown in FIG. In this case, A to C in Figure 3
and the structure as explained with reference to FIG. 4 is obtained. On the other hand, when the rotors of the first group and the second group are each rotated by 180 degrees, the structure is as described with reference to A to C of FIG. 1 and FIG. 2.

In this weaving, beating can be performed as necessary, and by adjusting the degree of beating and winding speed, each yarn 2a, 2b in the three-dimensional fabric can be
, 12 can be adjusted. Also,
By changing the movement area of the carrier during weaving, it is possible to obtain a three-dimensional fabric whose cross-sectional shape is changed during weaving.

FIG. 9 shows a three-dimensional fabric in which the orientation angles of the yarns are partially different. Such a three-dimensional fabric is produced by performing one cycle of steady weaving on the entire cross-sectional shape of the three-dimensional fabric in a weaving apparatus as shown in FIG.
Next, one steady cycle of weaving is performed on only the upper half, and then the weaving of the entire cross section and only the upper half are sequentially repeated. This is advantageous when stresses in different directions act on a rotating blade having such a structure.

In FIGS. 10 to 12, each A shows the external shape of a helicopter rotor blade, an ATP blade, and an aircraft propeller blade, which are examples of the rotary blade of the present invention, and each B shows the main parts thereof. It shows. In FIG. 10B, 51 is an outer shell structure, 52 is a weight part, and 53 is a honeycomb structure part, of which the outer shell structure 51 is made of the above-mentioned three-dimensional fabric. Further, in FIG. 11B, 55 is an outer shell structure, 56 is a solid spar, and 57 is a honeycomb filler, of which the outer shell structure 55 is made of the above-mentioned three-dimensional fabric. Further, in FIG. 12B, 59 is an outer shell structure, 60 is a hollow spar, and 61 is a foam, of which the outer shell structure 59 is made of the above-mentioned three-dimensional fabric.

[0026]

[Effects of the Invention] As is clear from the detailed explanation above, according to the present invention, by optimizing the orientation of reinforcing fibers,
It is possible to obtain a rotary blade and a method for manufacturing the same that solve the problem of peeling of laminated materials and at the same time achieve further weight reduction.

[Brief explanation of drawings]

FIGS. 1A to 1C illustrate the structure of the first embodiment of the three-dimensional fabric constituting the rotating blade of the present invention in three directions perpendicular to each other (
FIG. 3 is an explanatory diagram showing a state seen from a plane, an end surface, and a side surface.

FIG. 2 is an explanatory diagram showing the structure of the three-dimensional fabric in a perspective view.

FIGS. 3A to 3C are explanatory diagrams showing the structure of the second embodiment as viewed from three mutually orthogonal directions (plane, end surface, and side surface);

FIG. 4 is an explanatory diagram showing the structure of the three-dimensional fabric of the second embodiment in a perspective view.

FIG. 5 is a perspective view showing the appearance of an I-type three-dimensional fabric having the structure of the second embodiment.

FIG. 6 is a perspective view showing the weaving state of the three-dimensional fabric.

7 is a perspective view of main parts showing details of the carrier drive mechanism in FIG. 6. FIG.

FIG. 8 is an explanatory diagram regarding the manner of rotational driving of the rotor.

FIG. 9 is a perspective view showing the appearance of a three-dimensional fabric in which yarn orientation angles are partially different.

FIG. 10A is a plan view of a rotor blade for a helicopter, which is an example of the rotary blade of the present invention, and FIG. 10B is an enlarged perspective view showing a main part thereof cut away.

FIG. 11 A is an example of the rotating blade of the present invention.
A perspective view of a blade for TP, and B is an enlarged sectional view thereof.

FIG. 12A is a perspective view of an aircraft propeller blade which is an example of the rotary blade of the present invention, and FIG. 12B is an enlarged sectional view thereof.

[Explanation of symbols]

2a, 2b, 12 thread, 3, 13, 23, 28 Core thread, 20, 25 Three-dimensional textile, 32 Yarn carrier, 34 Rotor, 35 Recess.

Claims (3)

[Claims] Claim 1: A three-dimensional fabric having a cross-sectional shape necessary for a rotating blade, in which the three-dimensional fabric has the following features:
In the vertical plane, the threads are oriented at an appropriate angle with respect to the length direction of the three-dimensional fabric, and in the horizontal plane, the threads are oriented at an appropriate angle with respect to the length direction of the three-dimensional fabric. A large number of yarns are woven together so as to be continuous in the length direction by folding them back on the surface of the fabric, and core threads oriented linearly in the length direction of the three-dimensional fabric are provided in all or part of the cross section of the fabric. A rotating blade that uses a three-dimensional woven fabric. [Claim 2] A three-dimensional fabric having a cross-sectional shape necessary for a rotating blade, in which the three-dimensional fabric has the following features:
A large number of threads are inclined at an appropriate angle with respect to the length direction of the three-dimensional fabric in the vertical plane, and are inclined at an appropriate angle with respect to the length direction of the three-dimensional fabric in the horizontal plane,
Each fabric is woven continuously in the length direction by being folded back on the surface of the fabric, and core threads oriented linearly in the length direction of the three-dimensional fabric are woven into the entire or part of the cross section of the fabric. A rotating blade that uses three-dimensional fabric. 3. A large number of rotors sandwiching yarn carriers between adjacent rotors are arranged adjacent to each other in multiple rows and multiple columns, and the four circumferences of each adjacent rotor correspond to the weaving shape of the three-dimensional fabric. When one adjacent rotor rotates, the thread carrier is moved using the concave part of the other rotor as a guide, and this process is repeated to weave the three-dimensional fabric that constitutes the rotating blade. In this process, the yarn carriers are arranged to match the cross-sectional shape of the rotating blade, core yarns are led out in the length direction of the three-dimensional fabric from the central part of the necessary rotor in the arrangement, and a large number of rotors are Among them, the rotors that are not adjacent to each other in the above rows and columns are considered as one group, and the whole is divided into two groups, and the rotors of one group are used as non-rotating fixed guides and the other groups are set at 90° or 180° in one direction. rotate it,
Next, the other groups are rotated 90° or 180° in the opposite direction to the above using the first group of rotors rotated as a fixed guide, and by repeating this sequentially, the three-dimensional fabric is rotated in the length direction. A method for manufacturing a rotating blade using a three-dimensional fabric, characterized in that the threads are woven with each other in an inclined state, and the threads are oriented in a direction that increases the strength of the rotating blade.