DE2007217A1 - Method and device for producing fiber-reinforced articles - Google Patents

Description

pA'iFNTANWÄLfp

DIPL-ING. CURT WALLACH

DIPL.-ING. GÜNTHER KOCH 2007 217

DR. TINO HAIBACH

8 Munich 2.17. February 1970

OUR MARK: 12 471 -

Rolls-Royce Limited, Derby, Derbyshire, England.

Method and device for producing fiber-reinforced Objects

The invention relates to a method for producing fiber-reinforced Objects, e.g. fiber-reinforced, streamlined shaped blades, for a gas turbine jet engine.

The invention is based on a method for the production of a fiber-reinforced article, the fibers of which in at least two perpendicular directions. According to the invention, the method is carried out in such a way that a group of first pasers of each object is wound around a certain part of the same, such that several superimposed layers of the first pasers arise, and that then at least one group of further Pasern forms a layer or several layers that are perpendicular to run through the layers of the first pasers and interspersed with the latter and / or intertwined.

According to a further feature of the invention, a method for the simultaneous production of two fiber-reinforced articles, in which the fibers run in two mutually perpendicular directions, carried out in such a way that

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first a group of first fibers is wrapped around adjacent parts of the two objects so that several superimposed Layers of first pasers are formed, and that for each object at least one group of further pasers forms a layer or layers which are perpendicular to the layers of the first fibers and interspersed with the latter are, and that the articles thus produced are then separated from one another.

The layers of further Pasern can be between the formation successive layers of the first filaments are introduced over each predetermined area of the articles.

At least one layer of material may be in the vicinity of the adjacent parts between the formation of successive layers the first passers are inserted.

The further fibers can be introduced by means of a pressurized fluid medium.

Each of the objects can be potted ready.

According to an embodiment of the invention, if successive Parts of objects are built up, carriers are introduced to support them.

The first Pasers can be at an angle with respect to the longitudinal axis of the items being wrapped.

The further fibers can be introduced by wrapping them around the objects perpendicular to the first strands will.

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The pasers can be made into fiber-reinforced tapes of uncured or partially cured synthetic resin material may be provided, the synthetic resin material each layer is compacted and at least partially cured or further cured before the next layer is formed will.

According to a further embodiment of the invention, the method for the production of at least one fiber-reinforced object with two fiber groups running perpendicular to one another carried out in such a way that a group of first strands of the article is continuously wound around a carrier so as to form multiple superimposed layers of first pasers and that between production over any one at least one group of further fibers inserted between the first and further fibers in a predetermined region of the carrier or is intertwined.

According to one embodiment of the invention, each group of the further strands has ends that are anchored to the carrier, and the other Pasern are introduced by the fact that the opposite Ends of the group or groups of further strands are reciprocated perpendicular to the group of the first fibers.

In this case there are preferably two groups of further fibers provided, the fibers of each group being perpendicular to the first fibers and to each other and one of the groups further pasers is shot through with the first pasers and the other group of other fibers is intertwined with the first fibers.

Instead, the other Pasers can also be blown in be introduced into their position.

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Preferably, several interconnected fiber-reinforced objects are produced on the carrier at the same time, which will later be separated from each other.

Each of the fiber-reinforced articles can have a thickened section at one longitudinal end, which is produced in that at least one material layer is inserted between the superposed layers. In this way, the material can be introduced across the first group of fibers from one longitudinal side to the opposite longitudinal side.

The arrangement can be made so that whenever the respective end of the material is the opposite Long side of the first group of pasers that Material is separated in the area adjacent to the one longitudinal side, a relative movement is caused, as it is between the Layers of the material and the successive layers of first fibers at the thickened section is required to form this.

The winding is preferably effected by rotating the carrier continuously.

After each successive stacked layer is made in the predetermined area, it can be severed to give the fiber-reinforced article the corresponding To give shape, the shape being such that the contours of the successive layers joined together differ from each other.

The fibers can be uncured or incompletely cured synthetic resin impregnated and the

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Procreation of the fiber-reinforced article is made by heating completed in a mold for curing or completing the curing of the synthetic resin material.

The fibers can be in the form of fiber-reinforced synthetic Resin tapes may be provided.

The invention also relates to a device for generating at least of a fiber-reinforced article whose fibers are in at least two mutually perpendicular directions run. According to the invention, this device is designed in such a way that in that means are provided for continuously wrapping a group of the first fibers of the article around the carrier so as to that several superposed layers are formed, and that means are provided between the production of these layers over a predetermined area of the carrier at least introduce a group of further fibers perpendicular to the group of first fibers, these first and further fibers penetrating and / or are intertwined.

The invention also relates to a fiber-reinforced article, E.g. a fiber-reinforced, streamlined blade, for a flow machine, which according to the above Process was generated.

Exemplary embodiments of the invention are described below with reference to the drawing. In the drawing show: 1 is a schematic perspective view of a fiber-reinforced, streamlined blade for an oast turbine jet engine,

FIGS. 2 to 4 are schematic views of parts of the device, which was used to produce the blade according to Fig.l, Fig. 5 is a schematic perspective view of another fiber-reinforced, streamlined blade for an oast turbine jet engine,

6 is a schematic perspective view showing the simultaneous production of two fiber-reinforced, streamlined compressor rotor blades of a gas turbine jet engine illustrated, FIG. 7 is a schematic sectional view of the two blades, FIG. 6 is a schematic perspective view showing the simultaneous production of two fiber-reinforced, streamlined compressor rotor blades of a gas turbine engine in another embodiment of the invention.

Fig. 1 shows a streamlined blade 10, * for example in the form of a compressor rotor blade Gas turbine jet engine. The blade 10, which has a thickened blade root 11, has fibers 12,13,14 which in three perpendicular directions through the Shovel run down. The fibers 12, 12 and 14 are referred to below as radial fibers or axial fibers or circumferential fibers, because the fibers 12, 12, 14 are radial or axial or in the circumferential direction run when the blade 10 is installed.

The fibers 12,13 and 14 may be carbon fibers, for example, of polyacrylonitrile and with uncured or incompletely cured synthetic resin material), for example an epoxy resin, are getränl t. The blade root 11 also has layers 15 made of fiber-reinforced glass.

The fibers used can be used in the form of pre-impregnated ropes or in the form of impregnated dry fibers impregnated with a synthetic resin, in the vicinity of the device, where they are used to create the blades to be used.

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The fibers 12, 13 and 14 can also consist of silicon or boron and used to reinforce a metallic matrix or a matrix made of carbon instead of one Matrix made of epoxy resin or other synthetic resin material.

The device for producing the blade according to Pig.l consists from a hexagonal rotatable carrier 16 (Fig.2), the six Has surfaces 17 over which the radial fibers 12 are wound from a supply reel 20. By rotating the carrier

16, the fibers 12 are continuously wound on the carrier 16, so that several superimposed layers are made Radial fibers 12 arise.

The radial fibers 12 according to Figure 2 are continuously from a running thread is formed, but in practice it is expedient to use sheets of such fibers or threads or fiber-reinforced synthetic resin tapes wound around the carrier 16.

As can be seen from Figure 3, the device is with a pack 21 which reciprocates by means not shown can be, namely between the fully extended position in which it lies on a longitudinal side of the radial fibers 12, and the position shown in phantom, in which it lies on the opposite long side. The pack 21 carries the further ends of the axial fibers 13 * their opposite ends Ends are anchored to the support 16 by means not shown. Between the time periods in which consecutive Layers of radial fibers 12 over each predetermined area

17 are built up, the package 21 is moved perpendicular to the radial fibers 12, so that the radial fibers 12 and the Axial fibers 13 run alternately. That is, the reciprocating movement of the package 21 transversely to the one made of fibers Sheet 12 creates alternating layers, consisting of radial fibers 12 and axial fibers 13

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The running in the circumferential direction Pasern l4 are with their Ends anchored at points 22 that are spaced apart from one another and extend transversely to the one made of radial fibers 12 Sheet. The free ends of the fibers 14 running in the circumferential direction are held by a carrier 25 which is perpendicular to the badial fibers 12 is moved between the formation of successive layers of radial fibers 12 on each surface 17. Accordingly, when the circumferential fibers 14 are moved perpendicular to the radial fibers 12 from one side of the same to the other are intertwined with these. However, the interweaving between the fibers 12, 14 does not form a conventional woven bandage, since the circumferential fibers 14 alternate to opposite sides of the respective radial fibers of the superimposed layers run, but the radial fibers 12 do not run in opposite directions Pages of successive radially spaced fibers 14 are guided.

Between the formation of the superimposed layers of radial fibers 12 on each surface 17, a sheet 24, e.g. of the end 26 of the surface 17 which is closer to the pack 20. The plate 25 is by a spring 27 radially with respect to the Carrier 16 pressed outwards. The arrangement is such that whenever the corresponding end of the sheet 24 the Long side 30 of the sheet of radial fibers 12 has reached the sheet 24 in an area close to the opposite Page 31 of the sheet consisting of radial fibers 12 severed will. Successive layers 15 are introduced into that part which will later be the blade root 11 of the finished Shovel forms, each such layer 15 being inserted between layers of radial fibers 12 that are fitted one on top of the other will. So the sheet 24 transversely from the page 31 to the page 30 is supplied and so that such a supply is possible, the plate ^ 5 is radially inward through the passage of the Sheet 24 pressed. This creates the necessary relative movement between the planes of the blade 24 and the following layer of radial fibers 12 on the blade root 11, whereby the the latter is formed.

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If in each case a radial fiber layer 12 is deposited on the surface 17, it can by means not shown be cut off to allow adaptation to the respective contour of the finished blade, the latter is designed so that the contours of the successive superposed layers of radial fibers 12 differ from one another differentiate.

By the method described shovel-shaped fiber-reinforced objects are created, which with each other are connected. However, as shown schematically in Pig. 4, these interconnected objects are represented by a reciprocating knife 30 separated from each other.

Then the shovel-shaped objects from the surface of the carrier 16 is removed and the blades are produced from these objects by heating in a mold, wherein the curing of the synthetic resin material takes place or is completed.

As can be seen from the drawing, the radial fibers 12 are wound around the carrier 16 in that the latter is rotated will. It is of course also possible to keep the carrier 16 stationary and the supply reel around the carrier to circle.

Before the radial fibers 12 are wound onto the surfaces 17 of the carrier 16, the surfaces 17 can be covered with sheets of paper are covered, finally by the fiber-reinforced objects can be stripped off.

5 shows a blade 34, the blade foot 35 of which is made of radial fibers 36 and axial fibers 37 is penetrated. The latter run perpendicular to the radial fibers 36. The blade 34 points

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Layers of blade root material 39. The shovel according to Pig.5 is produced in that the radial fibers continuously 36 are wound up on a carrier, not shown, such that two blades 34 are produced at the same time, which are then separated from each other. This winding results in several superimposed layers Radial fibers 36 and having one of these layers over the part of the carrier that holds the respective blade are made, at least one but if possible two or more Layers of axial fibers 37 withdrawn from a supply 38 or blown off. At the same time, layers of blade root material are made 39 is inserted, e.g. in the same way as described with reference to PigO.

After separating the two blades 34, each blade arranged in a form where the thickened blade root 35 * is generated as shown.

In the embodiment shown in FIGS. 7 and 8, two gas turbine engine compressor rotor blades 40, 41 are used generated whose blade roots 42, 43 are adjacent to one another, but whose blade profiles are reversed with respect to the position of the convex and concave sides, and these two blades are produced at the same time.

This production takes place in that two blade root inserts 44, 45 are arranged on opposite sides of a stationary carrier 46. A spool 47 carries ribbons 50 of fiber-reinforced uncured synthetic resin material, for example epoxy resin reinforced with carbon fibers made of polyacrylonitrile. The coil 47 is adjacent to the Schaufelfußeinsätze 44,45 along a path 51 out and at the end of each rotation of the spool 47 is moved axially forward or back, as shown by the

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Arrows 52 indicated. Instead, the coil 47 could also are moved along a helical path.

The strands of the ribbons 50 form a group of first fibers, which are wrapped in this way around the adjacent blade root inserts 44, 45 so that several superimposed Layers 53 of these first strands are formed thereover. At the end of the creation of each layer 53, however, the coil becomes 47 between the formation of successive layers 53 stopped instantly. When the bobbin 47 is stopped, becomes a layer 54 of synthetic resin material that is reinforced with fiberglass, inserted over each of the opposite sides of the blade root inserts 54,55 and in addition becomes a ply 55 of further fibers on the sides of the respective Layers 54 introduced remotely from carrier 46. The sink 47 then starts moving again and creates the next layer 53, etc.

The layers 54 are produced in that material lengths of two pairs of rollers 56 (only one pair is shown) with the pairs of rollers 56 respectively above and below the blades 40 and 41 and each length of material is fed perpendicular to the fibers of the layer 53 and through non-illustrated means cut to length.

The fibers of the layers 55 are formed by individual fibers, e.g., carbon fibers, made from polyacrylonitrile and are introduced perpendicular to the strands of the layers 53. The pasers of layers 55 are initially held in carriers arranged on opposite sides of the blades 40, 41 and blown into their position by compressed air. The position of the fibers of the layers 55 can be controlled automatically so that the blades 40, 41 are given the required shape.

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So the layers 54,55 are intertwined with the layers 55, to which they run perpendicular.

As indicated at 60, the straps 50 can be at an angle be employed against the longitudinal axis of the blades 40.4l.

When successive parts of the blades 4O, 4l built up are, holders 61 are moved through slots of the carriers 57 to hold the successive parts.

After completion of each layer 55 and before generation of the next layer 55, a compression and curing or partially curing may take place w.

When the blades 40, 41 are completely finished, are they are separated along a cutting line 72 and, if necessary, brought to their final shape, although this is taken into account the previous work steps and curing is not necessary.

The method shown in FIG. 6 is that according to FIGS. 6 and 7 similar and for this reason a detailed description is not required. Corresponding parts are here provided with the same reference numerals. As can be seen in Figure 6, a spool 47 is used to wrap the straps 50 around the blade root inserts 44.45 to wrap. In addition, for the sake of clarity, the rollers 56 and carriers 61 are not shown, while in practice such parts are to be provided.

In the embodiment according to Fig.b, however, the Pasern are the Layers 55 according to Figure 6 and Ί replaced by fibers of ribbons 65 made of fiber-reinforced uncured synthetic resin material, e.g. epoxy synthetic resin reinforced with carbon fibers, which are made from polyacrylonitrile. As with the fibers of the layers 55, the ribbons O, i become orthogonal to the beams

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50 out and inserted between these. This is caused by the fact that the tapes 63 from reels 64 (one each for the blades 4O, 4l) and by guiding each coil 64 on a circulating path 65, after each layer 53 is completed and before the next layer is made.

After the formation of each layer 53 and the layer of tapes 63 the layer is compacted and cured or partially hardened.

The blades 40, 41 are finally longitudinally of one another Cut lines 62 separated and, if necessary, subjected to a final shaping.

If necessary, the blades 40, 41 can be formed around mold cores. If the mold cores are removable, hollow blades can be produced in this way.

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Claims (1)

Patent claims: Process for the production of at least one fiber-reinforced article, the reinforcing fibers of which in at least two directions perpendicular to one another, characterized in that a group of first stripes (23) around a certain part (14,15) of the object is wound so that several superimposed layers of first fibers (23) are formed are and that at least one group of further Pasern (25) is provided, one perpendicular to the layers of Form the first fibers running layer, these layers interpenetrating and / or being intertwined. 2. The method according to claim 1, characterized in that a group of first fibers (23) around adjacent portions (14,15) the objects are wrapped in such a way that several superimposed layers are formed from the first fibers, that each object is provided with at least one group of further fibers (25) which are perpendicular thereto form running layers and are intertwined with these layers, and that the two objects are then separated from each other be separated. 3. The method according to claims 1 or 2, characterized in that that the or each group of further pasers (25) of the production of successive layers (23) from first Pasern is introduced in a predetermined area. 4. The method according to claims 2 and 3 *, characterized in that at least one layer (24) in the vicinity of the adjacent parts (14,15) between the production of successive layers (2j>) of the first fibers is introduced. 009834/1717 5 process according to claims 2 to 4, characterized in that the further pasers are introduced by a pressure medium will. 6. The method according to claims 1 to 5> characterized in that each object is subsequently subjected to a final shape machining is subjected. 7. Method according to Claims 1 to 6, characterized in that carriers (6l) are filled in when the objects are being built will. Ö. Method according to claims 1 - Ί,
characterized in that the first strands are wound at an angle with respect to the longitudinal axis of the objects (10, 11). 9 process according to claims 2 to 6, characterized in that the further fibers (53) are introduced by that they are wound onto the objects perpendicular to the first fibers. 10. The method according to claims 1 to 9> characterized in that the fibers are uncured as fiber-reinforced tapes (20) or partially cured synthetic resin material may be used, the resin material of each layer compacted and at least partially cured or further cured before the next layer is produced. 0 Q ft 8 3 Λ / 1 7 1 7 11. The method according to claim 1, characterized / that continuously a group of first fibers (12) of the Object is wound on a carrier (16) so that several superimposed layers of first fibers (12) are formed and that between the production of the individual layers over a predetermined area of the At least one group of further fibers (13, 14) is inserted into the carrier perpendicular to the group of the first fibers in such a way that that an interweaving and / or penetration of the fibers (12-14) takes place. 12. The method according to claim 11, characterized in that the or each group of further fibers has ends, which are anchored to the carrier and that the further fibers are introduced by the fact that the opposite ends of the group or groups of further fibers (13, 14) are moved back and forth perpendicular to the group of the first fibers (12). 13 method according to claim 12, characterized in that two groups of further fibers (13, 14) are provided, which each extend perpendicular to the first fibers (12) and perpendicular to one another, and that a group of the further fibers (13) is penetrated with the first fibers (12), and that the other group (14) of the further fibers with the first Fibers (12) is shot through. 14. The method according to claim 11, characterized , that the other fibers are brought into place by blowing. 0 Π 9 8: U / 1 7 1 7 15. Process according to Claims 11 to 14, characterized in that that several interconnected fiber-reinforced objects, which are finally separated from one another, at the same time are generated on the carrier. 16. The method according to claims 11 to 15 , characterized in that each fiber-reinforced article has a thickened portion at one longitudinal end, which is produced in that at least one material layer is placed between the superimposed layers (12). 17 method according to claim 16, characterized in that the material transversely to the first group of fibers by one Long side is inserted after the opposite long side. Ib. Method according to claim 17, characterized in that whenever the feedstock (24) the opposite Long side of the first group of pasers (12) has reached the material in the area adjacent to this Long side is severed, and that a relative movement between the planes of the material and the successive Layering the first fibers is effected on the thickened portion so that it can be made. 19 process according to claims 11 to Ib, characterized , that the winding is effected by rotating the carrier continuously. 009834/1717 20. The method according to claims 11 to 19, characterized in that that after the production of each superimposed layer a cutting to adapt to the respective contour of the fiber-reinforced article takes place, this article is designed so that the contours are superimposed Layers differ from each other. 21. The method according to claims 11 to 20, characterized in that that the fibers are impregnated with uncured or incompletely cured synthetic resin and that h is completed the formation of the fiber-reinforced article by heating the latter in a form for the purpose of curing. 22. The method according to claim 21, characterized in that the fibers are in the form of fiber-reinforced synthetic Resin tapes can be used. 2Y. Method according to claims 11 to 22, characterized , that the fiber-reinforced article is a fiber-reinforced, streamlined blade of a turbomachine > is. 24. Device for performing the method, according to the Claims 1 to 23, for the production of a fiber-reinforced Object in which the fibers run in at least two perpendicular directions, characterized in that a carrier (16) and means are provided which are continuous wrap a group of first fibers around the carrier, 009834/1717 so that several superimposed layers of first fibers (12) arise, and that means are provided which are effective between the formation of the layers to be in a predetermined To introduce at least one group of further fibers perpendicular to the group of first fibers in the region (17) of the carrier, so that the fibers are mutually interwoven or interwoven. 0G9im / 1717