公开(公告)号：US11440273B2

公开(公告)日：2022-09-13

申请号：US16367350

申请日：2019-03-28

Applicant: ROLLS-ROYCE plc

Inventor： Vincent Gill

IPC: B29C70/34 ,  B29C70/44 ,  B29C70/54 ,  F01D5/28 ,  B29L31/08

Abstract: A method of forming a composite article involves the steps of: providing a formed article, the formed article comprising a plurality of non-crimp fibre fabrics with each non-crimp fibre fabric comprising at least two dry-fibre layers; stabilising the plurality of non-crimp fibre fabrics; machining a surface of the formed article having exposed ply terminations to provide a smooth blended surface with chamfered plydrops; positioning the machined formed article in a second mould; infiltrating the second mould with a polymer matrix resin; and curing the machined formed article to form the composite article.

公开(公告)号：US11441429B2

公开(公告)日：2022-09-13

申请号：US16277420

申请日：2019-02-15

Applicant: ROLLS-ROYCE plc

Inventor： Vincent Gill

IPC: F01D5/14 ,  F01D5/28 ,  B29C70/36 ,  B29C70/54 ,  B29C70/70 ,  B29L31/08 ,  B32B1/00 ,  B32B5/06 ,  B32B5/26 ,  B32B38/00 ,  B32B38/18 ,  B29C70/08 ,  B29C70/12 ,  B29C70/34 ,  B29C70/68 ,  B29D99/00 ,  B29C70/30

Abstract: A method of manufacturing a composite fan blade with an outer part and a core includes laying up a plurality of continuous plies to achieve a stack, placing the core on a central portion of the stack of continuous plies to achieve an unfolded preform; folding the contin-uous plies about the core, such that the central portion of the stack folds about the core and the first portion is superimposed to the second portion, to achieve a folded preform; apply-ing pressure to the folded preform to achieve a consolidated curved folded preform; curing the consolidated curved folded preform to achieve the composite fan blade.

公开(公告)号：US11187084B2

公开(公告)日：2021-11-30

申请号：US16277402

申请日：2019-02-15

Applicant: ROLLS-ROYCE plc

Inventor： Robert C Backhouse ,  Vincent Gill

IPC: B29C70/30 ,  F01D5/14 ,  F01D5/28 ,  B29C70/36 ,  B29C70/54 ,  B29C70/70 ,  B29L31/08 ,  B32B1/00 ,  B32B5/06 ,  B32B5/26 ,  B32B38/00 ,  B32B38/18 ,  B29C70/08 ,  B29C70/12 ,  B29C70/34 ,  B29C70/68 ,  B29D99/00

Abstract: A method of manufacturing a fan blade for a gas turbine engine. The method includes providing a compression mould having an internal mould surface corresponding to an outer profile of a fan blade, providing opposing first and second laminates to form a shell corresponding to the mould surface, each laminate comprising a lay-up of plies of fibre reinforcement material, applying a core material comprising quasi-isotropic short fibre reinforced resin in the compression mould so that with the compression mould in a moulding configuration the core material is enclosed by the shell, the core material and the shell forming a pre-form for the fan blade, applying pressure to compress the pre-form so that it conforms to the mould surface, and applying heat to cure the pre-form.

公开(公告)号：US10858944B2

公开(公告)日：2020-12-08

申请号：US16277494

申请日：2019-02-15

Applicant: ROLLS-ROYCE plc

Inventor： Vincent Gill

IPC: F01D5/14 ,  F01D5/28 ,  B29C70/36 ,  B29C70/54 ,  B29C70/70 ,  B29L31/08 ,  B32B1/00 ,  B32B5/06 ,  B32B5/26 ,  B32B38/00 ,  B32B38/18 ,  B29C70/08 ,  B29C70/12 ,  B29C70/34 ,  B29C70/68 ,  B29D99/00 ,  B29C70/30

Abstract: There is disclosed a method of manufacturing a fan blade for a gas turbine engine, the method comprising: providing a root insert comprising quasi-isotropic short fibre reinforced resin, providing a first sub-laminate of a fibre-reinforcement pre-form for the fan blade on a first mould surface, placing the root insert on the first sub-laminate at a position corresponding to a root of the fan blade, providing a second sub-laminate of the pre-form over the root insert and the first-sub-laminate, so that the root insert is at an intermediate position between the first and second sub-laminates; and applying heat and pressure to form the pre-form.