• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    Method of Forming a Composite Article and Composite Article The present invention generally relates to methods for making composite structures. more specifically, this invention relates to a method of manufacturing a composite article to have an integral composite secondary structure, for example, an integral flange of a composite housing for a turbomachine. the method of forming a composite article (10), which has a primary composite structure and an integral secondary composite structure that extends out of a plane defined by a continuous reinforcing material in the primary composite structure, comprises the steps of storing the first layers (18) to build the primary composite structure, which contain the continuous reinforcing material and extend from a first zone (12) that will define the primary composite structure into a second zone (14) that will define the secondary composite structure ; and during storage of the first layers, interspersing additional layers (20) with the first layers (18) within the second zone (14), but not the first zone (12), so that the second zone contains both the first and the additional layers, the additional layers originating within an accumulation zone (16) between the first and second zones (12, 14) and extending therefrom to the second zone; and deforming the accumulation zone and the first layer and the additional layers interspersed in said zone to orient the second zone and form the secondary composite structure extending outwardly from the plane defined by the continuous reinforcing material of the first layers.
    公开号:BR112014026869B1
    申请号:R112014026869-0
    申请日:2013-04-18
    公开日:2021-05-11
    发明作者:Ming Xie；Benjamin Ferrell；Bowden Kirk Patrick；Elliott Keller Schulte；Mark Ernest Vermilyea；Mitchell Harold Boyer
    申请人:General Electric Company；
    IPC主号:
    专利说明:

    FIELD OF THE INVENTION
    [001] The present invention relates generally to methods for manufacturing composite structures. More specifically, this invention relates to a method of manufacturing a composite article to have an integral composite secondary structure, for example, an integral flange of a composite housing for a turbomachine. BACKGROUND OF THE INVENTION
    [002] Composite materials generally comprise a fibrous reinforcement material incorporated into a matrix material which, in the case of a polymeric composite material, is a polymeric material (polymeric matrix composite, or PMC - Polymer Matrix Composite). The fibrous reinforcement of a composite material serves as the secondary constituent of the material, while the matrix material protects the reinforcement, maintains the orientation of its fibers and serves to dissipate loads on the reinforcement.
    [003] Composite materials have become increasingly popular for use in a variety of aerospace applications due to their durability and relatively light weight. Particular, but not limiting, examples include the use of PMC materials in fan casings for aircraft gas turbine engines. While composite materials can provide superior strength and weight properties, designing flanges and other secondary attributes into structures made from composite materials is a challenge. As an example, composite structures that have laminate formats that contain continuous reinforcing materials are capable of exhibiting superior in-plane strength due to the presence of the continuous reinforcing fibers. As used herein, continuous reinforcement materials refer to continuous fibers or fiber bundles (bundles) that are typically oriented to have a specific (unidirectional) orientation in a composite matrix material, for example, parallel to the direction of load on the composite, in contrast to non-continuous fibrous reinforcement materials made from short fibers that are typically randomly dispersed in a matrix material. While composite structures that contain continuous reinforcement fibers are able to exhibit superior in-plane strength, flanges and other secondary structures that extend out of the plane of continuous reinforcement fibers do not have continuous fibers at their attachment points, or at joints , with the primary composite structure. The absence of continuous fibers, as well as the likelihood of significant out-of-plane loads created by connections to the flanges, can result in relatively weaker bonding joints that are susceptible to damage from increased stresses. While it is possible to manufacture a flange separately and then bond the flange to a primary composite structure with a supplementary reinforcing structure, eg additional fibers or metal supports, the weight-saving benefits possible with the use of composite materials can be reduced significantly as a result of this.
    [004] In the case of composite gas turbine engine housings, integral flanges constructed from preformed fiber designs have been proposed to deal with structural weaknesses at the point of attachment. However, such options for preformed fiber designs tend to be somewhat limited. The layers used in the construction of composite housings and their integral flanges are typically braided or braided preforms that limit fiber orientation, resulting in the fact that stiffness and strength cannot be readily optimized. The degree of intercalation between the fiber bundles in the casing and the flange body is also typically limited, resulting in limited resistance to delamination.
    [005] Accordingly, there is a need for improved techniques by which a composite structure can be fabricated to have an integral composite flange or other secondary composite structure with continuous fibers at connection points therebetween. DESCRIPTION OF THE INVENTION
    [006] The present invention provides a method for manufacturing a composite article comprising a primary composite structure and at least one integral secondary composite structure, for example, a composite housing having an integral flange and the composite article formed therefrom, wherein continuous fibers are present within a binding region between the primary and secondary composite structures. The present invention further provides a method for making a composite article comprising an internal accumulation zone.
    [007] According to a first aspect of the invention, a method is provided for forming a composite article to have a primary composite structure and an integral secondary composite structure that extends outward from a plane defined by a continuous reinforcing material in the structure. primary composite. The method includes storing the first layers to build the primary composite structure. The first layers contain the continuous reinforcement material and extend from a first zone that will define the primary composite structure to a second zone that will define the secondary composite structure. During storage of the first layers, the additional layers are interspersed with the first layers within the second zone, but not the first zone, so that the second zone contains both the first layer and additional layers. The additional layers originate within an accumulation zone between the first and second zones and extend therefrom to the second zone. After interleaving the layers, the first layer and the additional layers, all interleaved, within the accumulation zone are deformed to orient the second zone and form the secondary composite structure that extends outward from the plane defined by the continuous reinforcement material of the first layers .
    [008] According to a second aspect of the invention, a composite article includes a primary composite structure comprising a continuous reinforcement material and an integral secondary composite structure that extends outwardly from a plane defined by the continuous reinforcement material in the composite structure primary. The primary composite structure includes the first layers that contain the continuous reinforcing material and the secondary composite structure comprises the first layers and additional layers. The additional layers originate within an accumulation zone between the primary composite structure and the secondary composite structure and extend therefrom to the secondary composite structure.
    [009] According to a third aspect of the invention, a method is provided for forming a composite article having an accumulation zone. The method includes storing the first layers to build the composite article. During storage of the first layers, the additional layers are interspersed with the first layers within the accumulation zone, but not the first zone, so that the accumulation zone contains both the first and additional layers.
    [010] A technical effect of the invention is the ability to fabricate a primary composite structure to have an integral composite secondary structure with a relatively strong bonding region with the primary composite structure without significantly increasing the weight of the composite article. In particular, it is believed that by providing the first layers with a continuous reinforcing material in the primary composite structure, continuing the first layers in the secondary composite structure and interspersing the additional layers with the first layers to form the secondary composite structure, the resulting composite article is able to exhibit improved bond strength between the first and second composite structures compared to prior bonding methods known in the art.
    [011] Other aspects and advantages of this invention will be better evaluated from the following detailed description. BRIEF DESCRIPTION OF THE DRAWINGS
    [012] Figure 1 is a schematic cross-sectional view depicting the individual layers of a composite article in accordance with one aspect of this invention.
    [013] Figure 2 is a schematic view representing the orientations of different layers that can be incorporated in the flange and accumulation zones of the preliminary composite article of Figure 1.
    [014] Figure 3 is a schematic cross-sectional view depicting the individual layers of a composite article in accordance with one aspect of this invention. DESCRIPTION OF ACHIEVEMENTS OF THE INVENTION
    [015] The present invention will be described in terms of processes for producing composite articles that are formed from a laminated material reinforced with fibers to comprise a primary composite structure that incorporates at least an integral secondary composite structure. The secondary composite structure extends out of a plane defined by the continuous reinforcing material in the primary composite structure. While various applications can be envisioned and possible, applications of particular interest include those that require relatively light weight components, for example, gas turbine components, including aircraft gas turbine engines. Composite articles with integral composite flanges, for example aircraft gas turbine engine fan housings, are of particular interest. Other possible secondary structures may include, but are not limited to, the reinforcing ring and structural bulkhead in the carcass structures.
    [016] While the teachings of the invention can be extended to apply to a variety of composite materials, PMC materials are of particular interest. Furthermore, although the invention may make use of a wide variety of fiber reinforced laminate materials, the laminate materials believed to be of particular interest to the invention contain continuous reinforcement materials formed from one or more of the following: fiberglass, graphite fibers, carbon fibers, ceramic fibers, aromatic polyamide fibers such as poly(p-phenyleneterephthalamide) fibers (ie KEVLAR®). The fibers of the continuous reinforcement material may be present as individual fibers or, more preferably, as bundles of fibers (bundles) which, as used herein, refers to an untwisted bundle of continuous reinforcement fibers.
    [017] For the purpose of manufacturing a PMC material, laminated materials additionally comprise a liquid resin that, after curing or solidification of the resin, will form a solid matrix material for the reinforcing material in the final composite article. Resins can be broadly classified as thermosetting or thermoplastic. Thermoplastic resins are generally categorized as polymers that can be repeatedly softened and drained when heated and hardened when cooled sufficiently due to a physical change rather than a chemical change. Notable exemplary classes of thermoplastic resins that can be used with the invention include nylons, thermoplastic polyesters, polyaryletherketones, and polycarbonate resins. Specific examples of high performance thermoplastic resins that have been considered for use in aerospace applications include polyether ether ketone (Polyetheretherketone - PEEK), polyether ketone ketone (Polyetherketoneketone - PEKK), polyetherimide (Polyetherimide - PEI) and polyphenylene sulfide (Polyphenylene Sulfide - PPS). In contrast, once fully cured to a hard, hard solid, thermoset resins do not undergo significant softening when heated, but instead thermally decompose when sufficiently heated. Notable examples of high performance thermoset resins that have been considered for use in aerospace applications include epoxy and polyester resins.
    [018] According to a preferred aspect of the invention, the primary composite structure can be fabricated to have the integral secondary structure defined at least in part by continuous fibers or fiber bundles (bundles) of the continuous reinforcement material originating from from within the body of the primary composite structure. A fiber reinforced laminated material (structure) comprising multiple pre-impregnated layers that contain the continuous fibers or fiber bundles can be stored to build the primary composite structure. As mentioned herein, a layer is an individual layer which contains a continuous reinforcing material and which is capable of providing complete coverage of a surface region, for example an underlying layer of laminated material. The continuous reinforcement material in successive layers of the primary composite structure preferably has different fiber orientation angles. After storage, the layers at one end of the primary composite structure are formed out of plane of the layers (and their continuous reinforcement material) to define the secondary structure.
    [019] The secondary structure is additionally constructed to contain the additional pre-impregnated layers that are interspersed with the layers of the primary composite structure. The additional layers of the secondary structure also contain the continuous reinforcement material. The additional layers of the secondary structure may have the same fiber orientation with respect to adjacent layers of the primary composite structure with which the additional layers are interspersed. For the purpose of promoting the rigidity and/or strength of the secondary structure and its bonding with the primary structure, the additional layers of the secondary structure preferably have different fiber orientation angles with respect to each adjacent layer of the primary composite structure with which an additional layer is interleaved. The thickness of the additional layers forming the secondary structure can also be adapted to increase the thickness of the secondary structure. These additional layers can also originate at various locations within the primary structure relative to the secondary structure, which results in the ends of the additional layers being alternated to minimize stress concentration. The accumulation of the primary composite structure and its secondary composite structure can be facilitated by directly depositing individual fiber layers or fiber bundles onto a tool surface, for example, using an automated fiber laying machine and a machine of filament winding. These machines allow for economical placement of fiber bundles in a varied fiber orientation and with varying degrees of interleaving.
    [020] Figure 1 schematically represents a preliminary composite structure 10 of the type described above, in which the cover layers 18 denote a first group of layers within a cover zone 12 that will define at least a portion of a structure primary composite, and portions of the cover layers 18 within a flange region 14 will be formed out of plane of the cover layers 18 to define a secondary composite structure, e.g., a flange. An accumulation zone 16 is defined between the cover and flange zones 12 and 14, within which cover layers 18 will be deformed (not shown) to result in portions of cover layers 18 within flange zone 14 being oriented. out of plane, e.g. perpendicular, to the covering zone 12 (and hence the primary composite structure within the covering zone 12). Figure 1 represents layers 18 as stored on a surface 24 of a tool 22.
    [021] As shown in Figure 1, the accumulation zone 16 comprises a tapered zone 16A and a zone of uniform thickness 16B. Flange and accumulation zones 14 and 16 contain additional accumulation layers (strata) 20 which are interspersed with covering layers 18, which can be seen in Figure 1 as being continuous through the entire extent of the covering zones and of flange 12 and 14. Unlike conventional sets of procedures known in the art, one or more accumulation layers 20 are depicted as interspersed preferably within each individual cover layer 18 rather than between two adjacent cover layers 18. The layers of accumulation zone 20 are shown in Figure 1 as originating at different locations within the tapered zone 16A of the accumulation zone 16, preferably for the purpose of achieving a substantially uniform thickness within the zone of uniform thickness 16B of the accumulation zone 16, as well as inside the flange zone 14. The ends of the continuous cover layers 18 and the inter accumulation layers sides 20 within flange region 14 are preferably chamfered or otherwise terminated in a manner, as shown in Figure 1, so that, after forming the secondary composite structure of layers 18 and 20 within flange region 14, the ends of layers 18 and 20 forming the secondary composite structure will define an end surface which is substantially parallel to the surface 24 of a tool 22 on which the preliminary composite structure 10 is fabricated. Chamfering the layers 18 and 20 within the flange zone 14 allows the continuous reinforcing material (fibers or fiber bundles) close to the tool surface 24, whether covering layers 18 or accumulation layers 20, to have a larger radius of curvature when bent and yet be flush with the ends of layers 18 and 20 further away from the tool surface 24.
    [022] Figure 2 schematically represents a way in which different layer orientations can be incorporated in the flange and accumulation zones 14 and 16 by interspersing the cover layers 18 and the accumulation layers 20 to promote the strength of the secondary composite structure (defined by flange zone 14) and the connection thereof (defined by accumulation zone 16) to the primary composite structure (defined by cover zone 12). In the example, an accumulation layer 20 having a β-β fiber orientation is sandwiched in a cover layer 18 between fibers having the θ-θ and α-α fiber orientations to result in the combination of depicted fiber orientations at the far right of Figure 2.
    [023] Suitable fiber diameters, bundle diameters and centre-to-centre bundle/fiber spacings within the continuous reinforcement materials of the cover of accumulation layers 18 and 20 will depend on the particular application of the thickness of layers 18 and 20 and other factors. In particular embodiments of the invention, about one to approximately eight fiber bundles per inch (approximately 2.5 to 20 cm) are used in the cover and accumulation layers 18 and 20 to construct the preliminary composite structure 10, and each bundle of fibers can comprise approximately 6,000 to 48,000 filaments of fiber. While such fiber filaments can be of any thickness, in particular embodiments, the thickness of the fiber filaments can be from approximately 0.075 to 0.25 mm (about 0.003 to approximately 0.010 inches).
    [024] Since layers 18 and 20 are stored on the tool surface 24, the secondary composite structure can be formed by deforming the accumulation zone 16 and portions of layers 18 and 20 therein to orient the flange zone 14 out of plane of the covering zone 12 and the layers 18 therein, after which the preliminary composite structure 10 can be thinned and cured. A person skilled in the art will understand how to determine the proper thinning and final cure parameters based on such factors as part size and resin used. At the end of the final cure, the tools 22 can be removed to obtain the resulting PMC article, including the primary and secondary composite structures discussed above.
    [025] From the foregoing, it should be noted that an integral flange (or other secondary structure) manufactured in the manner described above is capable of being lighter in weight than a flange that is formed separately and then bolted or joined to a composite carcass (or other primary structure). A large portion of the fiber bundles within the flange may be continuous fibers that originate within the shell, providing a higher load carrying capacity than a construction containing the non-continuous fibers. Furthermore, a flange constructed of individual fiber bundles with various fiber orientations and varying degrees of interleaving is able to provide far greater design flexibility than may be possible if preformed textile sheets (eg, braids and braids) are used. An additional advantage is that individual fiber bundles can be deposited with automated machines, thereby reducing manufacturing costs compared to processes that rely on manual storage.
    [026] According to an alternative embodiment of the invention, the composite structure 10 having the cover layers 18 can be formed through the above process to include a local accumulation (thickening) zone 16, shown in Figure 3. While the structure 10 does not form a secondary structure as in the previous embodiment, it can be anticipated that having the accumulation zone 16 may still be desirable in some applications, such as when the structure requires trimming or needs increased rigidity. The local accumulation zone 16 comprises two tapered zones 16A and a zone of uniform thickness 16B.
    [027] Although the invention has been described in terms of specific embodiments, it is clear that other forms can be adopted by a person skilled in the art. For example, the physical configuration of the primary and/or secondary composite structures may differ from that shown and materials and processes other than those cited may be used. Therefore, the scope of the invention is to be limited only by the following claims.
    权利要求:
    Claims (19)
    [0001]
    1. METHOD OF FORMATION OF A COMPOSITE ARTICLE (10), to have a primary composite structure and an integral secondary composite structure that extends outward from a plane defined by a continuous reinforcing material within the primary composite structure, characterized by comprising the steps of: storing the first layers (18) to build the primary composite structure, the first layers (18) containing the continuous reinforcement material and extending from a first zone (12) that will define the primary composite structure in a second zone (14) which will define the secondary composite structure, thereby defining the plane defined by a continuous reinforcing material within the primary composite structure; during storage of the first layers (18), intersperse additional layers (20) with the first layers (18) within the second zone (14), but not the first zone (12), so that the second zone (14) contains both the first and the additional layers (20), the additional layers (20) originating within an accumulation zone (16) between the first and second zones (12, 14) and extending therefrom to the second zone (14); and then deforming the accumulation zone (16) and the first layers (18) and additional layers (20) interspersed in said accumulation zone (16) to orient the second zone (14) and form the extending secondary composite structure out of the plane defined by the continuous reinforcement material of the first layers (18) in the primary composite structure.
    [0002]
    2. METHOD, according to claim 1, characterized in that the continuous reinforcement material comprises unidirectional fibers and the unidirectional fibers within the successive individual layers of the first layers (18) have different angles of fiber orientation.
    [0003]
    3. METHOD, according to claim 1, characterized in that the additional layers (20) contain a second continuous reinforcement material.
    [0004]
    4. METHOD according to claim 3, characterized in that the second continuous reinforcement material of at least one of the additional layers (20) has a different fiber orientation angle than the continuous reinforcement material of at least one of the first layers (18 ) with which the at least one additional layer is interleaved.
    [0005]
    5. METHOD according to claim 1, characterized in that each of the additional layers (20) is interspersed within an individual layer of the first layers (18).
    [0006]
    6. METHOD according to claim 5, characterized in that the additional layers (20) contain a second continuous reinforcement material and the second continuous reinforcement material of at least one of the additional layers (20) has a different fiber orientation angle of the continuous reinforcement material of one of the first layers (18) into which at least one additional layer is interspersed.
    [0007]
    7. METHOD, according to claim 1, characterized in that the additional layers (20) increase the thickness of the secondary composite structure in relation to the primary composite structure.
    [0008]
    8. METHOD according to claim 1, characterized in that the additional layers (20) originate in different locations within the accumulation zone (16) so that the ends of the additional layers (20) are alternated within the accumulation zone ( 16) to reduce the stress concentration in a joint region defined by the accumulation zone (16) between the primary and secondary composite structures.
    [0009]
    9. METHOD according to claim 1, characterized in that the first layer and the additional layers (18, 20) have ends that end at different locations within the second zone (14) so that an edge defined by the first layer and the layers additional (20) within the second zone (14) is chamfered after the storage step.
    [0010]
    10. METHOD according to claim 9, characterized in that the end defined by the first layers (18) and the additional layers (20) within the second zone (14) define an end surface that is parallel to the first layers (18) which form the primary composite structure after the deformation step.
    [0011]
    11. METHOD, according to claim 1, characterized in that the composite article (10) is a polymer matrix composite article.
    [0012]
    12. METHOD, according to claim 1, characterized in that the composite article (10) is a fan frame of a gas turbine engine and the integral secondary composite structure is a flange of the fan frame.
    [0013]
    13. COMPOSITE ARTICLE (10), characterized by having a primary composite structure and an integral secondary composite structure formed by the method, as defined in claim 1.
    [0014]
    14. COMPOSITE ARTICLE (10), comprising: a primary composite structure comprising a continuous reinforcing material; and an integral secondary composite structure that extends outwardly from a plane defined by the continuous reinforcing material within the primary composite structure; wherein the primary composite structure comprises first layers (18) comprising continuous reinforcing material, characterized in that the secondary composite structure comprises first layers (18) and additional layers (20), with the additional layers (20) originating within of an accumulation zone (16) between the primary composite structure and the secondary composite structure and extends therefrom to the secondary composite structure.
    [0015]
    An article (10) according to claim 14, characterized in that the continuous reinforcement material comprises unidirectional fibers and the unidirectional fibers within successive individual layers of the first layers (18) have different angles of fiber orientation.
    [0016]
    An article (10) according to claim 14, characterized in that each of the additional layers (20) is interleaved within an individual layer of the first layers (18).
    [0017]
    An article (10) according to claim 16, characterized in that the additional layers (20) contain a second continuous reinforcement material, and the second continuous reinforcement material of at least one of the additional layers (20) has an angle of fiber orientation different from the continuous reinforcement material of one of the first layers (18) within which at least one additional layer (20) is interspersed.
    [0018]
    An article (10) according to claim 14, characterized in that the additional layers (20) originate at different locations within the accumulation zone (16) so that the ends of the additional layers (20) are alternated within the zone. of accumulation (16) to reduce the stress concentration in a joint region defined by the accumulation zone (16) between the primary and secondary composite structures.
    [0019]
    An article (10) according to claim 14, characterized in that the composite article (10) is a polymer matrix composite article and a fan housing of a gas turbine engine, and the integral secondary composite structure is a flange of the fan housing.
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    同族专利:
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    CN104254439A|2014-12-31|
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    法律状态:
    2018-03-27| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2020-02-11| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
    2020-11-17| B06A| Notification to applicant to reply to the report for non-patentability or inadequacy of the application [chapter 6.1 patent gazette]|
    2021-03-23| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2021-05-11| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 18/04/2013, OBSERVADAS AS CONDICOES LEGAIS. |
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    优先权:
    申请号 | 申请日 | 专利标题
    US201261639900P| true| 2012-04-28|2012-04-28|
    US61/639,900|2012-04-28|
    US13/687,117|2012-11-28|
    US13/687,117|US10654246B2|2012-04-28|2012-11-28|Composite article and methods therefor|
    PCT/US2013/037095|WO2013162989A1|2012-04-28|2013-04-18|Composite article and methods therefor|
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