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US3615983A - Method of producing a fibrous article - Google Patents

Method of producing a fibrous article Download PDF

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Publication number
US3615983A
US3615983A US23174A US3615983DA US3615983A US 3615983 A US3615983 A US 3615983A US 23174 A US23174 A US 23174A US 3615983D A US3615983D A US 3615983DA US 3615983 A US3615983 A US 3615983A
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US
United States
Prior art keywords
fibrous material
assembly
lengths
transverse
recesses
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
US23174A
Other languages
English (en)
Inventor
Jack Palfreyman
Henry Edward Middleton
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Rolls Royce PLC
Original Assignee
Rolls Royce PLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Rolls Royce PLC filed Critical Rolls Royce PLC
Application granted granted Critical
Publication of US3615983A publication Critical patent/US3615983A/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/24—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least three directions forming a three dimensional structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/20—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres
    • B29C70/205—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres the structure being shaped to form a three-dimensional configuration
    • B29C70/207—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres the structure being shaped to form a three-dimensional configuration arranged in parallel planes of fibres crossing at substantial angles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2307/00—Use of elements other than metals as reinforcement
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1002—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina
    • Y10T156/1028—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina by bending, drawing or stretch forming sheet to assume shape of configured lamina while in contact therewith
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49316—Impeller making
    • Y10T29/49336—Blade making
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49801—Shaping fiber or fibered material

Definitions

  • the invention concerns a method of producing a fibrous article comprising employing at least one former at least one of whose surfaces is provided with substantially parallel recesses, laying a plurality of transverse lengths of fibrous material over the former so that the said transverse lengths extend transversely of the recesses and are spaced from each other longitudinally of the recesses, laying a longitudinal length of fibrous material in each said recess so that the said longitudinal lengths extend over the said transverse lengths and force respective portions of the latter into the recesses, forming at least one fibrous assembly having the shape of the respective said surface by bonding the transverse and longitudinal lengths together while the latter are on the former, and effecting relative separation between the said assembly and the former.
  • PATENTEDucr 28 I971 SHEET 2 [IF 2 METHOD OF PRODUCING A FIBROUS ARTICLE
  • This invention concerns a method of producing a fibrous article and although the invention is not so restricted it is more particularly concerned with a method of producing an aerofoil-shaped blade for use in a fluid flow machine such for example as a gas turbine engine.
  • blade is used in this specification in a broad sense as including bladelike members such as stator vanes.
  • a method of producing a fibrous article comprising employing at least one former at least one of whose surfaces is provided with substantially parallel recesses, laying a plurality of transverse lengths of fibrous material over the or each former so that the said transverse lengths extend transversely of the recesses and are spaced from each other longitudinally of the recesses, laying a longitudinal length of fibrous material in each said recess so that the said longitudinal lengths extend over the said transverse lengths and force respectiveportions of the latter into the recesses, forming at least one fibrous assembly having the shape of the respective said surface by bonding the transverse and longitudinal lengths together while the latter are on the former, and effecting relative separation between the or each said assembly and the former.
  • the transverse lengths are preferably constituted by portions of at least one common transverse length of fibrous material.
  • the transverse lengths are preferably constituted by portions of at least one common transverse length of fibrous material.
  • the said formers which are arranged in back-to-back relationship, the or each said common transverse length being wound around the respective pair of formers so that the said portions form parts of two said assemblies.
  • the longitudinal lengths are preferably constituted by portions of at least one common longitudinal length of fibrous material.
  • the said formers which are aligned with each other and are spaced from each other longitudinally of the recesses, the or each said common longitudinal length being wound around the respective pair of formers so that the said portions form parts of two said assemblies.
  • the assemblies are preferably separated from each other.
  • At least one layer of material may be arranged at one end of the or each said assembly and may be interconnected therewith by employing additional fibrous material which extends longitudinally of the assembly.
  • the additional fibrous material may be stitched through the said assembly.
  • the fibrous material may be fiber-reinforced mouldable material, the article being finally moulded.
  • the method may be employed to produce an aerofoilshaped blade for use in a fluid flow machine.
  • the invention also comprises a fibrous article when produced by the method set forth above.
  • FIGS. 1, 2, 4 and 5 illustrate diagrammatically various stages in a method of producing a fibrous article according to the present invention
  • FIG. 3 which is a sectional view taken on the line A-A of FIG. 2, illustrates the shape of the assembly produced after the stage of the method illustrated inFlG. 2 has been completed, and
  • FIG. 6 is a diagrammatic sectional view of the blade after the stage of the method illustrated in FIG. 5 has been completed.
  • the drawings illustrate diagrammatically the production of a fiber-reinforced compressor rotor blade of a gas turbine engine.
  • the fiber employed may, for example, be a carbon fiber produced from polyacrylonitrile, while this fiber may be used to reinforce a blade made of a mouldable synthetic resin material such, for example, as an epoxy resin.
  • the fibrous material may be metallic, e.g. of
  • the fibrous material may be coated with a metal (e.g. nickel) or with carbonaceous material.
  • a metal e.g. nickel
  • carbonaceous material e.g. nickel
  • the method will be described below on the basis that the blade is fonned from carbonaceous fibrous material produced from polyaerylonitrile, this fibrous material being coated with an uncured or partly cured epoxy resin.
  • a metal former I0 is employed having a surface 11 which is corrugated by reason of being provided with a plurality of substantially parallel longitudinally extending recesses 12.
  • the former 10 is treated with a release agent and a plurality of transverse lengths 13 of fibrous material are then laid over the former 10 so that the transverse lengths 13 extend transversely of the recesses 12 and are spaced from each other longitudinally of these recesses.
  • transverse lengths 13 are shown in FIG. 1 as being completely separate from each other, in practice it is more convenient to arrange that they are constituted by portions of at least one common transverse length of fibrous material. This may be easily effected by arranging that there is at least one pair of the formers 10 which are disposed in backto-back relationship, the or each said common transverse length being wound around the respective pair of fonners so that the said portions ultimately form part of two assemblies of fibrous material.
  • a longitudinal length 14 of fibrous material is laid in each recess 12 and is tensioned so that the said longitudinal lengths 14 extend over the said transverse lengths l3 and force respective portions of the latter into the recesses 12.
  • a size is applied to the assembly of lengths 13, 14 so as to bond these lengths together and to give this assembly the shape of the surface 11.
  • the longitudinal lengths 14 have been described above as though they were completely separate from each other, it is more convenient to arrange that they are constituted by portions of at least one common longitudinal length of fibrous material. This may for example be effected by providing at least one pair of the formers 10 which are longitudinally aligned with each other and are spaced from each other longitudinally with respect to the direction of the recesses 12, the or each said common longitudinal length being wound around the respective pair of formers 10 so that the said portions form parts of the two assemblies 15 which are ultimately produced.
  • pairsof formers are employed, they are subsequently removed and the fibrous assemblies formed on the various surfaces 11 are separated from each other.
  • the far ends of the longitudinal lengths 14 may, if desired, be clamped.
  • the longitudinal lengths 14 will, when the finished blade is mounted in a gas turbine engine, extend radially of the latter while the transverse lengths 13 will extend approximately axially thereof.
  • Such a finished blade requires a root portion 20 (FIG. 6) of increased thickness, and this root portion is therefore built up from a number oflayers 21 ofa material such. for
  • each said layer 2l' is arthe assembly in one direction, is stitched therethrough, and is then withdrawn (by separate means not shown) over the assembly in the opposite direction.
  • the layer of the additional fibrous material 22 may be appropriately cut to shape (by means not shown) so that the final blade has the desired form.
  • Two such blades may be formed simultaneously and then separated along the line 23.
  • a method of producing a fibrous article comprising employing at least one former at least one of whose surfaces is provided with substantially parallel recesses, laying a plurality of transverse lengths of fibrous material over the former so that the said transverse lengths extend transversely of the recesses and are spaced from each other longitudinally of the recesses, laying a longitudinal length of fibrous material in each said recess so that the said longitudinal lengths extend over the said transverse lengths and force respective portions of the latter into the recesses, forming at least one fibrous assembly having the shape of the respective said surface by bonding the transverse and longitudinal lengths together while the latter are on the former, and effecting relative separation between the said assembly and the former.
  • transverse lengths are constituted by portions of at least one common transverse length of fibrous material.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Moulding By Coating Moulds (AREA)
  • Laminated Bodies (AREA)
US23174A 1969-04-02 1970-03-27 Method of producing a fibrous article Expired - Lifetime US3615983A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB1723869 1969-04-02

Publications (1)

Publication Number Publication Date
US3615983A true US3615983A (en) 1971-10-26

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Family Applications (1)

Application Number Title Priority Date Filing Date
US23174A Expired - Lifetime US3615983A (en) 1969-04-02 1970-03-27 Method of producing a fibrous article

Country Status (4)

Country Link
US (1) US3615983A (da)
DE (1) DE2015802A1 (da)
FR (1) FR2038178B1 (da)
GB (1) GB1288566A (da)

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3893878A (en) * 1971-07-12 1975-07-08 Kaempen Industries Method for making a composite structure
US3915776A (en) * 1971-07-12 1975-10-28 Kaempen Industries Method for making composite structures
US3957416A (en) * 1971-07-12 1976-05-18 Kaempen Industries, Inc. Apparatus for making composite structures
US4376669A (en) * 1980-08-15 1983-03-15 The British Petroleum Company Limited Method of fabricating energy absorbing structure
US4381960A (en) * 1981-12-28 1983-05-03 United Technologies Corporation Method of manufacturing a filament wound article
US4671831A (en) * 1985-08-26 1987-06-09 Edo Corporation Fiber Science Division Method of manufacture of large high pressure composite bottles
US4695342A (en) * 1985-03-28 1987-09-22 General Motors Corporation Method of forming truck cab frames
US4863660A (en) * 1987-03-25 1989-09-05 Aerospatiale Societe Nationale Ind. Process for manufacturing composite reinforcement elements woven in three dimensions
US5047185A (en) * 1987-12-09 1991-09-10 Rudolf Engel Method of producing moldings
US5440806A (en) * 1992-03-13 1995-08-15 Mtu Motoren- Und Turbinen-Union Muenchen Gmbh Method of making blank for the manufacturing of fiber-reinforced coatings or metal components

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2684719B1 (fr) * 1991-12-04 1994-02-11 Snecma Aube de turbomachine comprenant des nappes de materiau composite.
FR2989020B1 (fr) * 2012-04-05 2014-12-12 Snecma Procede de fabrication d'une piece epaisse de turbomachine en materiau composite par injection de resine sous pression

Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3893878A (en) * 1971-07-12 1975-07-08 Kaempen Industries Method for making a composite structure
US3915776A (en) * 1971-07-12 1975-10-28 Kaempen Industries Method for making composite structures
US3957416A (en) * 1971-07-12 1976-05-18 Kaempen Industries, Inc. Apparatus for making composite structures
US4376669A (en) * 1980-08-15 1983-03-15 The British Petroleum Company Limited Method of fabricating energy absorbing structure
US4381960A (en) * 1981-12-28 1983-05-03 United Technologies Corporation Method of manufacturing a filament wound article
US4695342A (en) * 1985-03-28 1987-09-22 General Motors Corporation Method of forming truck cab frames
US4671831A (en) * 1985-08-26 1987-06-09 Edo Corporation Fiber Science Division Method of manufacture of large high pressure composite bottles
US4863660A (en) * 1987-03-25 1989-09-05 Aerospatiale Societe Nationale Ind. Process for manufacturing composite reinforcement elements woven in three dimensions
US5047185A (en) * 1987-12-09 1991-09-10 Rudolf Engel Method of producing moldings
US5440806A (en) * 1992-03-13 1995-08-15 Mtu Motoren- Und Turbinen-Union Muenchen Gmbh Method of making blank for the manufacturing of fiber-reinforced coatings or metal components
US5557846A (en) * 1992-03-13 1996-09-24 Mtu Motoren- Und Turbinen-Union Muenchen Gmbh Blank for the manufacturing of fiber reinforced coatings or metal components

Also Published As

Publication number Publication date
FR2038178B1 (da) 1974-07-12
DE2015802A1 (de) 1970-10-08
GB1288566A (da) 1972-09-13
FR2038178A1 (da) 1971-01-08

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