Airfoil with structural unit and method of forming

Abstract

An airfoil for a turbine engine has an outer wall defining an interior and an arc extending through the airfoil, and at least one cell within the interior. The at least one cell includes a forward portion and an aft portion relative to the arc. The forward portion and the aft portion can be connected by a side portion. A woven fabric can be provided on at least one of the forward portion or the aft portion, and a woven fiber can be provided on at least one of the side portions.

Description

TECHNICAL FIELD

[0001] The present disclosure relates generally to an airfoil having structural units within an interior of the airfoil. BACKGROUND

[0002] Turbine engines are rotary-type engines that extract energy from a flow of working air that is passed serially through a compressor section where the working air is compressed, a combustion section where fuel is added to the working air and ignited, and a turbine section where the combusted working air expands and gives up work to drive the compressor section and other systems, and provide propulsive thrust in aircraft applications. Compressor and turbine stages include pairs of rotating blades and stationary vanes arranged axially. Turbine engines can be arranged as engine cores that include at least a compressor section, a combustion section, and a turbine section arranged in axial flow, and define at least one rotating element or rotor and at least one stationary component or stator. A fan section can be provided upstream of the compressor section and draw ambient air into the core, and in bypass configurations, flow a portion of ambient air around the core.

[0003] Rotating blades and stationary vanes can be collectively referred to as airfoils within a turbine engine. Airfoils can be defined by an outer wall and an interior. The interior can include various structures for structural purposes. In some cases, the interior of an airfoil can include structural supports that reinforce the airfoil. BRIEF DESCRIPTION OF DRAWINGS

[0004] A complete and enabling disclosure of the present description, directed to one of ordinary skill in the art, is set out in the specification and includes the best mode of practicing the present description, as well as one or more best modes of practicing the present description, as contemplated by the inventor or inventors, and is illustrated in the accompanying drawings, in which:

[0005] Figure 1 is a schematic cross-sectional view of a turbine engine for an aircraft, the turbine engine including at least one airfoil.

[0006] Figure 2 is a perspective view of an airfoil that can be used as at least one airfoil of a turbine engine of Figure 1 , including an outer wall extending spanwise from a root to a tip and chordwise from a leading edge to a trailing edge.

[0007] Figure 3 is a top view of the airfoil of Figure 2 , including an arc extending through the airfoil.

[0008] Figure 4 is a cross-sectional top view of the airfoil from section IV-IV of Figure 2 , the airfoil including an interior, the interior including a first unit, a second unit, and a third unit, each unit including a respective shell.

[0009] Figure 5 yes Figure 4 A schematic diagram of one of the first, second, or third unit shells, the shell comprising woven fabric and woven fibers.

[0010] Figure 6 From Figure 4 The section VI-VI seen Figure 2 A cross-sectional side view of the airfoil.

[0011] Figure 7A It can be used as Figure 1 A schematic perspective view of at least one airfoil, the exemplary airfoil comprising a set of exemplary units linearly passing through the exemplary airfoil.

[0012] Figure 7B It can be used as Figure 1 A schematic perspective view of at least one airfoil, the exemplary airfoil comprising a set of exemplary units nonlinearly connected by the exemplary airfoil.

[0013] Figure 7C It can be used as Figure 1 A schematic perspective view of at least one airfoil, the exemplary airfoil comprising a set of exemplary units that pass non-linearly through the exemplary airfoil in a wave-like manner.

[0014] Figure 8A It can be used as Figure 1 A schematic top cross-sectional view of an exemplary airfoil, the exemplary airfoil comprising a set of exemplary units forming a set of unit nets extending linearly through the airfoil.

[0015] Figure 8B It can be used as Figure 1 A schematic top cross-sectional view of at least one airfoil, the exemplary airfoil comprising a set of exemplary units forming a set of unit nets extending linearly through the airfoil at an angle.

[0016] Figure 8C It can be used as Figure 1 A schematic top cross-sectional view of at least one airfoil, the exemplary airfoil comprising a set of exemplary units forming a V-shaped network of units through the airfoil.

[0017] Figure 8D It can be used as Figure 1 A schematic top cross-sectional view of an exemplary airfoil, the exemplary airfoil comprising a set of exemplary elements forming a set of element nets extending nonlinearly through the airfoil. DETAILED DESCRIPTION

[0018] The present disclosure relates to an airfoil for a turbine engine. As a non-limiting example, the present disclosure relates to a stationary vane provided within a fan section of a turbine engine. The airfoil can include a leading edge, a trailing edge, a tip, and a root. An outer wall can extend between the leading edge and the trailing edge in a chordwise direction and between the root and the tip in a spanwise direction. At least one cell can be provided within an interior. As used herein, at least one cell can be defined as a structural element provided within the interior of the airfoil and having a core and a shell extending around the at least one cell and between an interior portion of the outer wall of the airfoil and the core of the at least one cell. The at least one cell conforms to a contour of the outer wall. The shell of the at least one cell can include at least one fiber. The at least one fiber can include a woven fabric having a first fiber and a second fiber and extending across the entire shell and a woven fiber extending across only a portion of the shell.

[0019] As described herein, the at least one fiber of the at least one cell and the overall shape of the at least one cell can control the mechanical properties of the airfoil to best suit the operation of the turbine engine. The airfoil as described herein has better control over its mechanical properties as compared to a conventional airfoil that does not include at least one cell. As used herein, the term “mechanical properties” or iterations thereof can refer to the ability of the airfoil to withstand various stresses and forces when the turbine engine is in operation. The mechanical properties that can be controlled by the at least one cell can include, but are not limited to, airfoil stiffness, shear capability, torsional stiffness, or any other suitable mechanical property. It should be appreciated that the airfoils of the turbine engine as described herein can be universally applicable to any turbine engine, such as, but not limited to, a turbofan engine, a turboprop engine, a turboshaft engine, a turbofan engine with a power gearbox, or, in non-limiting examples, an unducted fan turbine engine. However, it should be appreciated that the aspects of the present disclosure described herein are not so limited and can have universal applicability within other turbine engines. For example, the present disclosure can be applicable to other engines or vehicles and can be used to provide benefits in industrial, commercial, and residential applications. It should be further appreciated that the aspects of the present disclosure described herein are not so limited and can be universally applicable to airfoils that are not in a turbine engine. For example, the present disclosure can be universally applicable to airfoils formed into wings, blades, propellers, and the like.

[0020] As used herein, the term “upstream” refers to a direction opposite to the direction of fluid flow, and the term “downstream” refers to a direction the same as the direction of fluid flow. The term “forward” or “front” denotes in front of something, and “aft” or “rear” denotes behind something. For example, when used in relation to fluid flow, forward / forwardly can denote upstream, and aft / aftly can denote downstream.

[0021] Further, as used herein, the term "radial" or "radially" refers to a direction away from a common center. For example, in the overall context of a turbine engine, radial refers to a direction along a ray extending between a central longitudinal axis of the engine and an outer engine circumference. Further, as used herein, the term "set" or "set of" elements can be any number of elements, including only one.

[0022] All directional references (e.g., radial, upper, lower, upward, downward, left, right, lateral, front, back, top, bottom, above, below, vertical, horizontal, clockwise, and counterclockwise) are only used for identification purposes to aid the reader’s understanding of the present disclosure, and do not constitute a limitation, specifically as to the position, orientation, or use of the disclosure. Connection references (e.g., attached, coupled, connected, and joined) are to be construed broadly and will be given their ordinary and accustomed meaning to an artisan of ordinary skill in the art, and will include intermediate members between the elements and intermediate connections to the elements. As used herein, connection references (e.g., attached, coupled, connected, and joined) do not exclude the presence of intermediate

[0023] Figure 1 is a schematic cross-sectional view of a turbine engine, particularly a turbine engine 10 for an aircraft. The turbine engine 10 has a generally longitudinally extending axis or engine centerline 12 that extends from a forward end 14 to an aft end 16. The turbine engine 10 includes, in downstream serial flow relationship, a fan section 18 including a fan 20, a compressor section 22 including a booster or low pressure (LP) compressor 24 and a high pressure (HP) compressor 26, a combustion section 28 including a combustor 30, a turbine section 32 including a HP turbine 34 and a LP turbine 36, and an exhaust section 38. The turbine engine 10 described herein refers to a non-limiting example, and other architectures are possible, such as but not limited to a steam turbine engine, a supercritical carbon dioxide turbine engine, or any other suitable turbine engine.

[0024] The fan section 18 includes a fan casing 40 surrounding the fan 20. The fan 20 includes a set of fan blades 42 arranged radially about the engine centerline 12. The HP compressor 26, the combustor 30, and the HP turbine 34 form an engine core 44 of the turbine engine 10 that produces combustion gases. The engine core 44 is surrounded by a core casing 46, which can be coupled with the fan casing 40.

[0025] A high pressure shaft or spool 48 coaxially disposed about the engine centerline 12 of the turbine engine 10 drivingly connects the HP turbine 34 to the HP compressor 26. An LP shaft or spool 50 coaxially disposed about the engine centerline 12 of the turbine engine 10 within the larger diameter annular HP spool 48 drivingly connects the LP turbine 36 to the LP compressor 24 and the fan 20. The spools 48, 50 are rotatable about the engine centerline 12 and are coupled to a set of rotatable elements that can collectively define a rotor 51.

[0026] The LP compressor 24 and the HP compressor 26 each include a set of compressor stages 52, 54 with a set of compressor blades 56, 58 rotating relative to a corresponding set of stationary compressor vanes 60, 62 (also referred to as nozzles) to compress or pressurize a fluid flow through the stage. In a single compressor stage 52, 54, multiple compressor blades 56, 58 can be provided in an annulus and can extend radially outward relative to the engine centerline 12 from a blade platform to a blade tip, with a corresponding stationary compressor vane 60, 62 located upstream and adjacent to the rotating compressor blades 56, 58. Note, Figure 1 The number of blades, vanes, and compressor stages shown in FIG. 1 is for illustrative purposes only, as other numbers are possible.

[0027] The compressor blades 56, 58 of the compressor stages can be mounted to a disk 61 that is mounted to a corresponding one of the HP and LP spools 48, 50, with a disk 61 for each stage. The stationary compressor vanes 60, 62 for the compressor stages can be mounted to the core casing 46 in a circumferential arrangement.

[0028] The HP turbine 34 and the LP turbine 36 each include a set of turbine stages 64, 66 with a set of turbine blades 68, 70 rotating relative to a corresponding set of stationary turbine vanes 72, 74 (also referred to as nozzles) to extract energy from a fluid flow through the stage. In a single turbine stage 64, 66, multiple turbine blades 68, 70 can be provided in an annulus and can extend radially outward relative to the engine centerline 12 from a blade platform to a blade tip, with a corresponding stationary turbine vane 72, 74 located upstream and adjacent to the rotating turbine blades 68, 70. Note, Figure 1 The number of blades, vanes, and turbine stages shown in FIG. 1 is for illustrative purposes only, as other numbers are possible.

[0029] The turbine blades 68, 70 of the turbine stages can be mounted to a disk 71 that is mounted to a corresponding one of the HP and LP spools 48, 50, with a disk 71 for each stage. The stationary turbine vanes 72, 74 for the compressor stages can be mounted to the core casing 46 in a circumferential arrangement.

[0030] In addition to the rotor portion, the stationary portion of the turbine engine 10, such as the static vanes 60, 62, 72, 74 in the compressor and turbine sections 22, 32, also individually or collectively referred to as the stator 63. As such, the stator 63 can refer to the combination of non-rotating elements of the entire turbine engine 10.

[0031] In operation, the airflow exiting the fan section 18 is split such that a portion of the airflow is directed into the LP compressor 24, which then supplies a pressurized airflow 76 to the HP compressor 26, which further pressurizes the air. The pressurized airflow 76 from the HP compressor 26 is mixed with fuel in the combustor 30 and ignited, creating combustion gases. The HP turbine 34 extracts some work from these gases, which drives the HP compressor 26. The combustion gases are discharged into the LP turbine 36, which extracts additional work to drive the LP compressor 24, and the exhaust is ultimately discharged from the turbine engine 10 via the exhaust section 38. The driving of the LP turbine 36 drives the LP spool 50 to rotate the fan 20 and the LP compressor 24. The pressurized airflow 76 and the combustion gases can together define a working airflow through the fan section 18, the compressor section 22, the combustion section 28, and the turbine section 32 of the turbine engine 10.

[0032] A portion of the pressurized airflow 76 can be extracted from the compressor section 22 as bleed air 77. The bleed air 77 can be extracted from the pressurized airflow 76 and provided to engine components that require cooling. The temperature of the pressurized airflow 76 entering the combustor 30 is significantly increased. Thus, cooling provided by the bleed air 77 is necessary for operating such engine components in an elevated temperature environment.

[0033] The remaining portion 78 of the airflow bypasses the LP compressor 24 and the engine core 44 and is discharged from the turbine engine 10 through stationary vanes, and more specifically, through an exit guide vane assembly 80 including a set of airfoil guide vanes 82 on the fan discharge side 84. The set of airfoil guide vanes 82 can define a set of stationary fan vanes. More specifically, a circumferential row of radially extending airfoil guide vanes 82 are used adjacent to the fan section 18 to impart some directional control to the airflow 78.

[0034] Some of the air supplied by the fan 20 can bypass the engine core 44 and be used to cool portions of the turbine engine 10, particularly hot portions, and / or to cool or power other aspects of the aircraft. In the case of a turbine engine, the hot portions of the engine are generally downstream of the combustor 30, particularly the turbine section 32, with the hottest portion being the HP turbine 34 since it is directly downstream of the combustion section 28. Other sources of cooling fluid can be, but are not limited to, fluid bled from the LP compressor 24 or the HP compressor 26.

[0035] Figure 2 is a perspective view of an airfoil 100 that can be used within a turbine engine 10 of Figure 1 FIG. 1. The airfoil 100 can be any suitable airfoil described herein. By way of non-limiting example, the airfoil can be a blade of a set of fan blades 42, an airfoil guide vane 82 (e.g., a set of stationary fan vanes), a static compressor vane 60, 62, a rotating compressor blade 56, 58, a rotating turbine blade 68, 70, or a static turbine vane 72, 74. However, the airfoil 100 will be described in terms of a vane that can be used in the fan section 18 or the compressor section 22.

[0036] The airfoil 100 can extend between a root 102 and a tip 104 to define a spanwise direction (S d ). The airfoil 100 can extend between a leading edge 106 and a trailing edge 108 to define a chordwise direction (C d ). The outer wall 110 can extend in the chordwise direction (C d ) between the leading edge 106 and the trailing edge 108 and in the spanwise direction (S d ) between the root 102 and the tip 104. The outer wall 110 can define a pressure side 112 and an opposing suction side 114 of the airfoil 100. The outer wall 110 can be formed by any suitable method and take any suitable shape. By way of non-limiting example, the outer wall 110 can be formed as a composite skin. Alternatively, the outer wall 110 can be a cast wall, an additively manufactured wall, or the like.

[0037] Figure 3 is a top view of a profile of the tip 104 of the airfoil 100 of Figure 2 FIG. 1. It should be appreciated that the profile of the airfoil 100 can vary between the root 102 and the tip 104.

[0038] The profile can be defined with reference to well-known terms used to define airfoils. For example, the profile can be defined by an arc line 116 extending from the leading edge 106 to the trailing edge 108 that is equidistant from the pressure side 112 of the outer wall 110 and the suction side 114 of the outer wall 110. While the airfoil 100 is shown to include the arc line 116 having a curve or camber, it should be appreciated that the airfoil 100 can include the arc line 116 without a curve, such as in a symmetrical airfoil, or without camber. A chord line 118 can be defined as a straight line distance from the leading edge 106 to the trailing edge 108. By way of non-limiting example, for a high camber airfoil as shown, a majority of the chord line 118 does not lie within the profile itself, but extends through the pressure side 112 region of the airfoil 100.

[0039] Figure 4 is a top view of a profile of the tip 104 of the airfoil 100 of Figure 2A cross-sectional top view of the airfoil 100 as seen in cross-section IV-IV. The outer wall 110 of the airfoil 100 can define an interior 120. At least one cell can be provided within the interior and provide structural support to the airfoil 100 to enhance its mechanical properties. As a non-limiting example, the at least one cell can include a first cell 122, a second cell 124, and a third cell 126. The first cell 122, the second cell 124, and the third cell 126 can each be defined by a shell 133 extending around a respective core 128.

[0040] The first cell 122, the second cell 124, and the third cell 126 can each be arranged relative to one another about the arc line 116. As a non-limiting example, the third cell 126 can be aft of the second cell 124, which can be aft of the first cell 122 relative to the arc line 116. At least a portion of the first cell 122 can correspond to the leading edge 106. At least a portion of the third cell 126 can face a portion of the interior 120 defined by an absence of material. Optionally, at least a portion of the third cell 126 can correspond to the trailing edge 108. Although three cells are shown, it should be understood that the airfoil 100 can include any number of one or more cells. The first cell 122, the second cell 124, and the third cell 126 can extend across any suitable percentage of the interior 120, with the remainder of the interior 120 being defined by an absence of any cells. As a non-limiting example, the first cell 122, the second cell 124, and the third cell 126 can extend across 50% of the interior 120.

[0041] Each cell can include a respective core 128 surrounded by a respective shell 133. The core 128 can be any suitable core, such as but not limited to a foam core, a metal core, or any combination thereof. Each shell 133 can include a forward portion 130, an aft portion 132, and opposing side portions 135 relative to the arc line 116. The forward portion 130, the aft portion 132, and the opposing side portions 135 can be integrally formed or continuous with one another in Figure 4 are shown in enlarged cross-section as distinct cross-sections. This is for illustrative purposes only. It should be understood that the forward portion 130, the aft portion 132, and the opposing side portions 135 can be integrally formed or continuous with one another. The shell 133 can completely enclose or encase the core 128. The shell 133 can face an interior portion of the outer wall 110 and an exterior portion of the core. In this way, the outer wall 110 and the core 128 can sandwich the shell 133 therebetween.

[0042] Each of the front portion 130, the rear portion 132, and the opposing side portions 135 can be defined by a first thickness 136, a second thickness 138, and a third thickness 139, respectively, relative to a plane that intersects the shell 133 and extends parallel to the arc line 116. At least one of the first thickness 136 and the second thickness 138 can be greater than, less than, or equal to the third thickness 139. As a non-limiting example, the first thickness 136 and the second thickness 138 can both be greater than the third thickness 139. The second thickness 138 and the first thickness 136 can be equal or unequal. The first thickness 136, the second thickness 138, and the third thickness 139 are shown with respect to the first cell 122 only. However, it should be appreciated that the second cell 124 and the third cell 126 can also be defined by the first thickness 136, the second thickness 138, and the third thickness 139. It should be appreciated that the first thickness 136, the second thickness 138, and the third thickness 139 can vary from cell to cell or between cells. As a non-limiting example, the first thickness 136 can be greater along the front portion 130 than the first thickness 136 along the rear portion of the front portion 130 relative to the arc line 116. As a non-limiting example, a portion of the first thickness 136 can decrease toward the opposing side portions 135. It is contemplated that a portion of the front portion 130 corresponding to and facing the leading edge 106 can have a greatest thickness. As a non-limiting example, the first thickness 136 of the first cell 122 need not equal the first thickness 136 of the second cell 124.

[0043] Adjacent portions of adjacent cells can define a cell web 134. As a non-limiting example, the rear portion 132 of the first cell 122 and the front portion of the second cell 124 can form a cell web 134, while the rear portion of the second cell 124 and the front portion 130 of the third cell 126 can form another cell web 134. It should be appreciated that the airfoil 100 can include any number of two or more cell webs 134. The rear portion 132 of the first cell 122 and the front portion 130 of the second cell form a cell web 134, while the rear portion 132 of the second cell 124 and the front portion 130 of the third cell 126 form a cell web 134. Each cell web 134 can extend across the interior 120 of the airfoil 100 in the spanwise direction (S d ) relative to the arc line 116. The cell webs 134 can be equally spaced relative to one another along the arc line 116. Alternatively, the spacing can not be equal.

[0044] Figure 5 is a portion of the shell 133 of Figure 4 As shown, the shell 133 can be the shell 133 of any of the first cell 122, the second cell 124, or the third cell 126.

[0045] The shell 133 can include at least one fiber. As a non-limiting example, the shell 133 can include a woven fabric 170 and a woven fiber 172. Both the woven fabric 170 and the woven fiber 172 can include at least two fibers. As used herein, the term “fiber” can refer to a continuous, filamentous or thread-like textile fiber that includes a synthetic or natural material. As a non-limiting example, the woven fabric 170 can include a first fiber extending along a first bias and a second fiber extending along a second bias. The first bias can be different from (e.g., non-parallel to) the second bias. As a non-limiting example, the woven fiber 172 can have a third bias. The third bias can be different from (e.g., non-parallel to) the first bias and the second bias. As used herein, the term “bias” as used with respect to a woven fiber can refer to an extension direction of one or more fibers forming the respective woven fiber. As a non-limiting example, the woven fabric 170 can include at least two fibers extending in non-parallel directions or otherwise intersecting one another. As such, a woven fabric or a woven fiber is formed as shown. Thus, the woven fabric 170 can include a multi-bias fiber defining the first bias and the second bias, while the woven fiber 172 can include a single-bias fiber defining the third bias. The at least one fiber can be any suitable fiber such as, but not limited to, a metallic fiber, a carbon fiber, or any combination thereof.

[0046] The woven fabric 170 and the woven fiber 172 can extend in any suitable direction. As a non-limiting example, the woven fabric 170 including a multi-bias fiber can be any suitable fiber extending in at least two opposing directions. As a non-limiting example, and as shown, the multi-bias fiber can include a first fiber extending in a first direction and a second fiber intersecting the first fiber at a single point and extending in a second direction that is non-parallel to the first fiber. As a non-limiting example, the woven fabric 170 can extend in both a spanwise direction (S d ) and a chordwise direction (C d ). This particular multi-bias fiber can be defined as a bi-axial fiber. However, it should be appreciated that the multi-bias fiber of the woven fabric 170 can be any suitable multi-bias fiber such as, but not limited to, a bi-axial fiber, a spiral fiber, or any other suitable woven or braided fiber. As a non-limiting example, the woven fiber 172 including a single-bias fiber can extend linearly or non-linearly in a generally single direction. As shown, the single-bias fiber of the woven fiber 172 can extend linearly in a spanwise direction (S d ). Alternatively, the single-bias fiber can extend in a serpentine manner or other non-linear manner in the spanwise direction (S d ). The woven fiber 172 can extend in any other suitable direction such as, but not limited to, a chordwise direction (C d ), or an axial or radial direction relative to the engine centerline 12.

[0047] The woven fabric 170 can extend through the entire shell 133. The woven fibers 172 can extend through at least a portion of the shell 133. As a non-limiting example, the woven fibers 172 can be provided along opposite side portions 135. Since the woven fabric 170 can extend through the entire shell 133, the woven fibers 172 can be woven or otherwise machined into the woven fabric 170. As shown, the woven fibers 172 can be machined or woven into opposite sides of the intersection points between opposite fibers of the woven fabric 170. Furthermore, the woven fabric 170 can be in the chord direction (C... d The spaces are evenly or unevenly spaced on the surface.

[0048] The shell 133 shown comprises only a single layer of at least one fiber. However, it should be understood that any number of one or more stacked layers of at least one fiber may be present, each extending outward from the core 128. Thus, regions of increased thickness can be formed (e.g., a first thickness 136 in the front portion 130 and a second thickness 138 in the rear portion 132).

[0049] Figure 6 From Figure 4 The cross section VV seen Figure 2 A cross-sectional side view of the airfoil component. The first unit 122, the second unit 124, and the third unit 126 can each be positioned in the spanwise direction (S... d It extends upwards and through the entire interior 120.

[0050] The first unit 122, the second unit 124, and the third unit 126 may each include a corresponding cap 174 provided at the distal end of the respective first unit 122, second unit 124, and third unit 126. As shown, the first unit 122, the second unit 124, and the third unit 126 may each include a corresponding cap 174 provided along a portion of the first unit 122, the second unit 124, and the third unit 126 corresponding to the tip 104 of the airfoil 100. Alternatively, the first unit 122, the second unit 124, and the third unit 126 may include a corresponding cap 174 provided along a portion of the first unit 122, the second unit 124, or the third unit 126 corresponding to the root 102 of the airfoil 100. Optionally, the first unit 122, the second unit 124, and the third unit 126 may include corresponding caps 174 provided along multiple portions of the first unit 122, the second unit 124, or the third unit 126 corresponding to the root 102 and the tip 104 of the airfoil 100.

[0051] During the manufacturing of the airfoil 100, the at least one fiber can be operatively coupled to the respective core 128 by any suitable method. As a non-limiting example, the at least one fiber can be woven on the core 128 by fiber weaving. As a non-limiting example, a woven fabric 170 having a first fiber extending along a first bias and a second fiber extending along a second bias can be woven on the core 128. A woven fiber 172 having a third bias can be woven on the core 128. As a non-limiting example, the woven fiber 172 can be woven into or knitted into the woven fabric 170. It should be appreciated that the weaving of the woven fabric 170 and the woven fiber 172 can also include weaving additional layers of the woven fabric 170 or the woven fiber 170 on layers that have already been woven of the woven fabric 172 or the woven fiber 172. This in turn can create regions of increasing thickness of the woven fiber (e.g., the first thickness 136, the second thickness 138, and the third thickness 139) along the core 128. The distal end of the core 128 can be open or not include the at least one fiber. Accordingly, a cap 174 can be positioned across or otherwise seal the distal end of the core 128. The cap 174 can be provided along one or both distal ends of the core 128. It should be appreciated that the method of weaving of the woven fabric 170 and the woven fiber 172 and the positioning of the cap 174 can be performed for each respective cell (e.g., the first cell 122, the second cell 124, and the third cell 126). The first cell 122, the second cell 124, and the third cell 126 can then be positioned adjacent to one another as they will be located within the interior 120 of the airfoil 100.

[0052] Once the respective cells including the at least one fiber are made, the cells can be placed within the interior 120 of the airfoil 100. Optionally, the outer wall 110 can be formed on the cells by any suitable method. It is contemplated that the core 128 can remain within the cells or can be further removed by any suitable method, such as burning, melting, leaching, or any combination thereof. As a non-limiting example, the core 128 can define a hollow interior or be absent of material. Each cell can be formed to correspond to a respective portion of the outer wall 110 of the airfoil, which will be placed against once the outer wall 110 is formed on or placed on the cell.

[0053] During operation of the turbine engine 10, the airfoil 100 can be placed under various stresses or forces based on the location of the airfoil 100. By way of non-limiting example, the airfoil 100 can be a vane provided within the fan section 18. In this case, the airfoil 100 would be subjected to external forces generated by the fluid flow passing over the airfoil 100. This, in turn, would exert vibrational forces on the airfoil 100. At least one cell can be provided to adjust the mechanical properties of the airfoil 100 to enable it to withstand the forces that will be exerted during operation. It should be appreciated that the forces experienced along the airfoil 100 can be non-uniform. Accordingly, each cell can include varying thicknesses (e.g., first thickness 136, second thickness 138, and third thickness 139), as well as varying weaves (e.g., first weave, second weave, and third weave) to reflect these non-uniform forces. By way of non-limiting example, varying the thickness and weave of at least one fiber can increase the stiffness of the airfoil 100. Furthermore, the airfoil 100 can include more than one cell such that a cell web 134 can be formed between adjacent cells. The cell web 134 can be used to increase the shear capacity of the airfoil 100. The increased stiffness and shear capacity can ultimately result in the airfoil 100 being suited for the particular forces that it will be subjected to during normal operation of the turbine engine 10. Furthermore, the spacing of the cell web 134 around the camber line 116 and the thickness of the woven fibers 172 along the cell web 134 can be used to adjust the stiffness of the airfoil 100 in the spanwise direction (S d ) of the airfoil 100. In other words, by adjusting the spacing of the cell web 134 and the thickness of the woven fibers 172, the stiffness of the airfoil 100 can be varied in the spanwise direction (S d ) of the airfoil 100.

[0054] Figure 7A is an exemplary airfoil 200 that can be used in a turbine engine 10 of Figure 1 . The exemplary airfoil 200 is similar to the airfoil 100, and thus, like parts will be identified with like numerals increased to the 200 series, it being understood that the description of like parts of the airfoil 100 apply to the airfoil 200 unless otherwise stated.

[0055] The airfoil 200 can include a root 202, a tip 204, a leading edge 206, and a trailing edge 208. An outer wall 210 can extend between the root 202 and the tip 204 in a spanwise direction, and between the leading edge 206 and the trailing edge 208 in a chordwise direction. The airfoil 200 can include at least one cell having at least one woven fiber. Each adjacent cell can form a cell web 234 through their adjacent woven fibers (e.g., adjacent back portions and front portions). Although a perspective view is shown from the exterior of the airfoil 200, a projection of the cell web 234 is shown.

[0056] Airfoil 200 is similar to airfoil 100, except that airfoil 200 includes a swept leading edge 206 and a trailing edge 208, whereas airfoil 100 includes a linear leading edge 106 and a trailing edge 108. It should be appreciated that airfoil 200 can include a linear leading edge 206 and a trailing edge 208 like airfoil 100, or take any other suitable airfoil shape.

[0057] As shown, cell web 234 can extend linearly from root 202 to a portion radially spaced from root 202. Thus, when viewed along a plane extending along an arc and intersecting root 202 and tip 204, cell web 234 can form a linear profile. While cell web 234 is shown extending at a perpendicular angle relative to the portion of root 202 with which it intersects, it should be appreciated that cell web 234 can extend linearly from root 202 at any suitable angle.

[0058] Figure 7B is an exemplary airfoil 300 that can be used in a turbine engine 10 of Figure 1 FIG. 7 is a schematic perspective view of an exemplary airfoil 300 that can be used in a turbine engine 10 of

[0059] Airfoil 300 can include a root 302, a tip 304, a leading edge 306, and a trailing edge 308. An outer wall 310 can extend between root 302 and tip 304 in a spanwise direction, and between leading edge 306 and trailing edge 308 in a chordwise direction. Airfoil 300 can include at least one cell having at least one braided fiber. Each adjacent cell can form a cell web 334 through their adjacent braided fibers (e.g., adjacent aft and forward portions). While a perspective view is shown from the exterior of airfoil 300, a projection of cell web 334 is shown.

[0060] Airfoil 300 is similar to airfoil 200 in that it includes a swept leading edge 306 and a trailing edge 308. It should be appreciated that airfoil 300 can take any other suitable airfoil shape.

[0061] As shown, cell web 334 extends from root 302 in a non-linear manner. As a non-limiting example, cell web 334 can follow the profile of leading edge 306. Alternatively, cell web 334 can follow the profile of trailing edge 308. Thus, when viewed along a plane extending along an arc and intersecting root 302 and tip 304, cell web 334 can form a non-linear profile.

[0062] Figure 7C is an exemplary airfoil 300 that can be used in a turbine engine 10 of Figure 1A schematic perspective view of an exemplary airfoil 400 in a turbine engine 10. The exemplary airfoil 400 is similar to airfoils 100, 200, and 300; therefore, similar portions will be identified by similar numbers increasing to the 400 series. It should be understood that, unless otherwise stated, the description of similar portions of airfoils 100, 200, and 300 applies to airfoil 400.

[0063] Airfoil 400 may include a root 402, a tip 404, a leading edge 406, and a trailing edge 408. Outer wall 410 may extend in the spanwise direction between the root 402 and the tip 404, and in the chordwise direction between the leading edge 406 and the trailing edge 408. Airfoil 400 may include at least one unit having at least one braided fiber. Each adjacent unit may form a unit mesh 434 through their adjacent braided fibers (e.g., adjacent rear and front portions). Although a perspective view of the airfoil 400 from the outside is shown, a projection of the unit mesh 434 is shown.

[0064] Airfoil 400 is similar to airfoils 200 and 300 in that it includes a swept leading edge 406 and a trailing edge 408. However, it should be understood that airfoil 300 can adopt any suitable airfoil shape.

[0065] As shown in the figure, the cell mesh 434 extends from the root 402 in a non-linear or non-uniform manner. As a non-limiting example, the cell mesh 434 can undulate in a wave-like form. Alternatively, the cell mesh 434 can extend in any suitable non-linear manner. Thus, when viewed along a plane that extends along an arc and intersects the root 402 and the tip 404, the cell mesh 434 can form a wave-like profile.

[0066] The mechanical properties of airfoils 200, 300, and 400 can be further adjusted by changing the element meshes 134, 234, 334, and 434. As a non-limiting example, variations between element meshes 134, 234, 334, and 434 can be used to adjust the airfoil's properties along the spanwise direction (S). d The stiffness of the airfoil, as discussed in this paper, allows for adjustment of the airfoil for its specific application within the turbine engine 10.

[0067] Figure 8A It can be used Figure 1 A schematic top cross-sectional view of an exemplary airfoil 500 in a turbine engine 10. The exemplary airfoil 500 is similar to airfoils 100, 200, 300, and 400; therefore, similar portions will be identified by similar numbers increasing to the 500 series. It should be understood that, unless otherwise stated, the description of similar portions of airfoils 100, 200, 300, and 400 applies to airfoil 500.

[0068] The airfoil 500 can include an outer wall 510 defining an interior 520. The airfoil 500 can also include an arc line 516. At least one cell can be provided within the interior 520. By way of non-limiting example, the airfoil 500 can include a first cell 522, a second cell 524, and a third cell 526. The first cell 522, the second cell 524, and the third cell 526 are shown schematically, and thus their woven fibers and core are not shown.

[0069] The cell web 534 can be formed as any of the cell webs 134, 234, 334, 434 described herein. However, the cell web 534 can extend linearly from one side of the outer wall 510 through the interior 520 to the other side. The cell web 534 can extend from the outer wall 510 at a perpendicular angle.

[0070] Figure 8B is an exemplary airfoil 600 that can be used in a turbine engine 10 Figure 1 A schematic top cross-sectional view of an exemplary airfoil 600 that can be used in a turbine engine 10. The exemplary airfoil 600 is similar to the airfoils 100, 200, 300, 400, 500, and thus, like parts will be identified with like numbers increased to the 600 series, it being understood that the description of like parts of the airfoils 100, 200, 300, 400, 500 apply to the airfoil 600 unless otherwise noted.

[0071] The airfoil 600 can include an outer wall 610 defining an interior 620. The airfoil 600 can also include an arc line 616. At least one cell can be provided within the interior 620. By way of non-limiting example, the airfoil 600 can include a first cell 622, a second cell 624, and a third cell 626. The first cell 622, the second cell 624, and the third cell 626 are shown schematically, and thus their woven fibers and core are not shown.

[0072] The cell web 634 can be formed as any of the cell webs 134, 234, 334, 434 described herein. Similar to the cell web 534, the cell web 634 can extend linearly from one side of the outer wall 610 through the interior 620 to the other side. However, the cell web 634 can extend from the outer wall 610 at a non-perpendicular angle that is greater than zero degrees. The cell web 534, 634 can each be defined by a linear profile when viewed in a plane parallel to the arc line 516, 616 and intersecting the first cell 522, 622, the second cell 524, 624, and the third cell 526, 626.

[0073] Figure 8C is an exemplary airfoil 600 that can be used in a turbine engine 10 Figure 1FIG. 7 is a schematic top cross-sectional view of an exemplary airfoil 700 in a turbine engine 10. The exemplary airfoil 700 is similar to the airfoils 100, 200, 300, 400, 500, 600, and thus, like parts will be identified with like numerals increased to the 700 series, it being understood that the description of like parts of the airfoils 100, 200, 300, 400, 500, 600 applies to the airfoil 700 unless otherwise stated.

[0074] The airfoil 700 can include an outer wall 710 defining an interior 720. The airfoil 700 can also include an arc line 716. At least one unit can be provided within the interior 720. By way of non-limiting example, the airfoil 700 can include a first unit 722, a second unit 724, and a third unit 726. The first unit 722, the second unit 724, and the third unit 726 are schematically illustrated, and thus their woven fibers and core are not shown.

[0075] The unit web 734 can be formed as any of the unit webs 134, 234, 334, 434 described herein. As shown, the unit web 734 can include two discrete portions or legs that form a V-shape. In other words, the unit web 734 can include a V-shaped profile when viewed in a plane parallel to the arc line 716 and intersecting the first unit 722, the second unit 724, and the third unit 726. As shown, the apex of the V-shape can be provided along the arc line 716. However, it is to be understood that the apex can be offset from the arc line 716. While shown as a V-shape, it is to be understood that the unit web 734 can be formed as any suitable non-linear profile, such as, but not limited to, a trapezoidal shape.

[0076] Figure 8D is a turbine engine 10 in which the exemplary airfoils described herein can be used Figure 1 FIG. 8 is a schematic top cross-sectional view of an exemplary airfoil 800 in a turbine engine 10. The exemplary airfoil 800 is similar to the airfoils 100, 200, 300, 400, 500, 600, 700, and thus, like parts will be identified with like numerals increased to the 800 series, it being understood that the description of like parts of the airfoils 100, 200, 300, 400, 500, 600, 700 applies to the airfoil 800 unless otherwise stated.

[0077] The airfoil 800 can include an outer wall 810 defining an interior 820. The airfoil 800 can also include an arc line 816. At least one unit can be provided within the interior 820. By way of non-limiting example, the airfoil 800 can include a first unit 822, a second unit 824, and a third unit 826. The first unit 822, the second unit 824, and the third unit 826 are schematically illustrated, and thus their woven fibers and core are not shown.

[0078] The cell net 834 can be formed as any of the cell nets 134, 234, 334, 434 described herein. As shown, the cell net 834 can be formed non-linearly. As non-limiting examples, the cell net 834 can be formed as a semi-circle. In other words, the cell net 834 can include a non-linear profile when viewed in a plane parallel to the arc 816 and intersecting the first cell 822, the second cell 824, and the third cell 826. As shown, the vertex of the non-linear profile can be provided along the arc 816. However, it should be appreciated that the vertex can be offset from the arc 816. While shown as a semi-circle, it should be appreciated that the cell net 834 can form any suitable non-linear profile, such as, but not limited to, an ellipse.

[0079] With reference to Figures 8A-8D The cell nets 534, 634, 734, 834 can be used to further adjust the mechanical performance of the respective airfoils. As non-limiting examples, variations between the cell nets 534, 634, 734, 834 can be used to adjust the response to impingement and torsion-bending coupling of the respective airfoils. This in turn allows for the airfoils to be tailored for their particular use within the turbine engine 10. It should also be appreciated that the example airfoils can include any of the cell nets 134, 234, 334, 434, 534, 634, 734, 834 or a combination of cell nets 134, 234, 334, 434, 534, 634, 734, 834 as described herein. As non-limiting examples, the example airfoils can include a first cell, a second cell, and a third cell. The cell net between the first cell and the second cell can be formed like the cell net 234 and the cell net 734, while the cell net between the second cell and the third cell can be formed like the cell net 334 and the cell net 634. Regardless, the contact portion of the cells can follow the same profile for two adjacent cells.

[0080] Benefits of the present disclosure include airfoils that are better suited for their particular use in a turbine engine as compared to conventional airfoils. For example, conventional airfoils can include structural support provided within the interior of the conventional airfoil. The structural support can be used to increase the mechanical properties of the conventional airfoil, however, it can be difficult to manufacture and relies on the existing construction of the conventional airfoil (e.g., the shape of the conventional airfoil). However, as described herein, the airfoil includes at least one cell with at least one fiber surrounding a core of the at least one cell. As discussed herein, the woven fiber can include a woven fabric and a woven fiber that can have different weaves and different thicknesses in the spanwise direction and the chordwise direction. This in turn means that the cells can be adjusted to provide mechanical properties to a particular portion of the airfoil according to the expected forces that the portion of the airfoil will experience. Further, the airfoil can include a plurality of cells (e.g., a first cell, a second cell, and a third cell) with cell webs formed between adjacent cells. The orientation of these cell webs can vary, further adjusting the mechanical properties of the airfoil. This in turn can result in the airfoil having higher and better adjusted mechanical properties for its intended use in a turbine engine as compared to conventional airfoils.

[0081] In areas where not yet described, different features and structures of the various aspects can be used in combination or substituted for each other as desired. The fact that one feature is not illustrated in all examples does not mean it cannot be so illustrated, but rather it is done for brevity of description. Thus, various features of different aspects can be mixed and matched as desired to form new aspects, whether or not the new aspects are expressly described. All combinations or permutations of features described herein fall within the scope of the present disclosure.

[0082] This written description uses examples to describe the aspects of the disclosure described herein, including the best mode, and also to enable any person skilled in the art to practice the aspects of the disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the aspects of the disclosure is defined by the claims, and can include other examples that occur to those skilled in the art. Such other examples are intended to fall within the scope of the claims if they have structural elements in common with the

[0083] Further aspects of the present disclosure are provided by the subject matter of the following clauses:

[0084] An airfoil for a turbine engine, the airfoil comprising: an outer wall defining an interior and an arc extending through the airfoil, the outer wall extending between a leading edge to a trailing edge to define a chordwise direction and between a root and a tip to define a spanwise direction; and at least one cell located within the interior and having a shell, the shell comprising: a front portion and a rear portion connected by side portions relative to the arc; a woven fabric having first fibers extending along a first diagonal and second fibers extending along a second diagonal different than the first diagonal, the woven fabric provided along the front portion, the rear portion, and the side portions; and a woven fiber extending along a third diagonal different than the first diagonal and the second diagonal, the woven fiber provided along at least one of the side portions.

[0085] The airfoil of any preceding paragraph, wherein the woven fiber is woven into the woven fabric.

[0086] The airfoil of any preceding paragraph, wherein a distribution of the woven fabric and the woven fiber is non-uniform along the at least one cell.

[0087] The airfoil of any preceding paragraph, wherein when viewed along a plane intersecting the shell and parallel to the arc, the front portion defines a first thickness, the rear portion defines a second thickness, and at least one of the side portions defines a third thickness that is less than or greater than the first thickness and the second thickness.

[0088] The airfoil of any preceding paragraph, wherein the first thickness is not equal to the second thickness.

[0089] The airfoil of any preceding paragraph, wherein the front portion faces an interior portion of the outer wall defining the leading edge.

[0090] The airfoil of any preceding paragraph, wherein the first thickness, the second thickness, and the third thickness are unequally with respect to a range of the front portion, the rear portion, and the at least one of the side portions, respectively.

[0091] The airfoil of any preceding paragraph, wherein when viewed along a plane extending along the arc and intersecting the root and the tip, at least one of the front portion or the rear portion is defined by a profile having a linear, non-linear, or wavy profile.

[0092] The airfoil of any preceding clause, wherein the at least one cell comprises a first cell and a second cell, the second cell being located aft of and adjacent to the first cell with respect to the arc, wherein a rear portion of the first cell contacts a front portion of the second cell, and wherein the profile of the rear portion of the first cell corresponds to a profile of the front portion of the second cell.

[0093] The airfoil of any preceding clause, wherein the profile follows a profile of the outer wall in the spanwise direction.

[0094] The airfoil of any preceding clause, wherein the at least one of the front portion or the rear portion is defined by a linear, non-linear, or V-shaped profile when viewed in a plane parallel to the arc and intersecting the front portion and the rear portion.

[0095] The airfoil of any preceding clause, wherein the at least one cell is comprised within a set of spaced apart cells having at least a first cell and a second cell, the second cell being located aft of and adjacent to the first cell with respect to the arc, and wherein a front portion of the second cell and a rear portion of the first cell face each other to form a cell web.

[0096] The airfoil of any preceding clause, wherein the cell web forms: at least one of a linear, non-linear, or V-shaped profile when viewed in a plane parallel to the arc and intersecting the front portion and the rear portion; and at least one of a linear, non-linear, or wave profile when viewed along a plane extending along the arc and intersecting the root and the tip; wherein each cell of the set of cells follows a profile of a portion of the outer wall against which it faces, and wherein each cell of the set of cells extends between the root and the tip of the outer wall.

[0097] The airfoil of any preceding clause, wherein the at least one cell comprises a core, and the shell surrounds the core, wherein the core is at least one of a sacrificial core or a non-sacrificial core, and wherein the woven fabric and the woven fibers are continuously woven on the non-sacrificial foam core during manufacture of the airfoil.

[0098] The airfoil of any preceding clause, wherein the turbine engine is a turbofan engine comprising a fan section, and wherein the airfoil is a bucket provided within the fan section.

[0099] An airfoil comprising: an outer wall defining an interior and an arc extending through the airfoil, the outer wall extending between a leading edge to a trailing edge to define a chordwise direction and between a root and a tip to define a spanwise direction; and at least one cell located within the interior and having a shell, the shell comprising: a front portion and a rear portion connected by side portions relative to the arc; a woven fabric having first fibers extending along a first bias and second fibers extending along a second bias different than the first bias, the woven fabric provided along the front portion, the rear portion, and the side portions; and a woven fiber extending along a third bias different than the first bias and the second bias, the woven fiber provided along at least one of the side portions.

[0100] The airfoil according to any preceding clause, further comprising a plurality of spaced apart cells having the at least one cell, wherein each of the plurality of spaced apart cells are axially spaced apart from each other relative to the arc.

[0101] The airfoil according to any preceding clause, wherein each of the plurality of spaced apart cells comprises a respective woven fabric having a respective first bias and a respective woven fiber having a respective second bias, and wherein at least one of the first bias or the second bias of one of the plurality of spaced apart cells can be different or the same, respectively, than the first bias or the second bias of another of the plurality of spaced apart cells.

[0102] A method of forming an airfoil, the method comprising: weaving a first woven fabric having first fibers extending along a first bias and second fibers extending along a second bias different than the first bias over a first core; weaving a first woven fiber along a second bias defined by a single bias fiber over a portion of the first core; and encasing at least a portion of a cell defined by the core, the first woven fabric, and the first woven fiber with a shell.

[0103] The method according to any preceding clause, further comprising: weaving a second woven fabric having first fibers extending along a first bias and second fibers extending along a second bias different than the first bias over a second core; weaving a second woven fiber along a third bias different than the first bias and the second bias over a portion of the second core; and positioning the second core adjacent to the first core.

Claims

1. A turbine engine characterized by, The turbine engine comprises: a fan section, a compressor section, a combustion section, and a turbine section in a serial flow arrangement; and an airfoil provided within at least one of the fan section, the compressor section, or the turbine section, the airfoil comprising: an outer wall extending between a leading edge to a trailing edge to define a chordwise direction and between a root and a tip to define a spanwise direction, the outer wall defining an interior, a pressure side, a suction side, and an arc line extending through the interior between the leading edge and the trailing edge equidistant between the suction side and the pressure side, the interior extending a first distance along the arc line; and a set of cells within the interior, the set of cells extending a second distance along the arc line, the second distance being less than the first distance, each cell of the set of cells having a shell comprising: a forward portion and an aft portion disposed behind the forward portion relative to the arc line, the forward portion and the aft portion connected by a side portion; and a woven fabric having first fibers extending along a first diagonal and second fibers extending along a second diagonal different than the first diagonal, the woven fabric provided along the forward portion, the aft portion, and the side portion.

2. The turbine engine of claim 1, wherein, wherein the airfoil further comprises a woven fiber woven into the woven fabric.

3. The turbine engine of claim 2, wherein, wherein a distribution of the woven fabric and the woven fiber is non-uniform along each cell of the set of cells.

4. The turbine engine of any one of claims 1-3, wherein, wherein the forward portion of the shell defines a first thickness, the aft portion defines a second thickness, and at least one of the side portions defines a third thickness when viewed along a plane intersecting the shell and parallel to the arc line, the third thickness being less than or greater than the first thickness and the second thickness.

5. The turbine engine of claim 4, wherein, wherein the first thickness is not equal to the second thickness.

6. The turbine engine of claim 5, wherein, wherein the forward portion of an axially forwardmost cell of the set of cells relative to the arc line faces an interior portion of the outer wall defining the leading edge.

7. The turbine engine of claim 4, wherein, wherein ranges of the first thickness, the second thickness, and the third thickness with respect to the forward portion, the aft portion, and the at least one of the side portions, respectively, are not equal.

8. The turbine engine of any one of claims 1-3, wherein, wherein at least one of the forward portion or the aft portion is defined by a profile in the spanwise direction, the profile having at least one of a linear, non-linear, or wavy profile.

9. The turbine engine of claim 1, wherein, wherein the set of cells comprises a plurality of cells.

10. The turbine engine of claim 1, wherein, wherein each cell of the set of cells comprises a profile in the spanwise direction following a profile of the outer wall in the spanwise direction.

11. The turbine engine of any one of claims 1-3, wherein, wherein the at least one of the forward portion or the aft portion comprises a profile in the chordwise direction defined by a linear, non-linear, or V-shaped profile.

12. The turbine engine of claim 9, wherein, wherein axially adjacent cells of the plurality of cells form a cell mesh between one another, the cell mesh extending in the spanwise direction.

13. The turbine engine of claim 12, wherein, wherein the cell mesh forms: at least one of a linear, non-linear, or V-shaped profile in the chordwise direction; and at least one of a linear, non-linear, or wavy profile in the spanwise direction; wherein each cell of the set of cells follows a contour of a portion of the outer wall it faces, and wherein each cell of the set of cells extends between the root and the tip of the outer wall.

14. The turbine engine of claim 2, wherein, wherein each cell of the set of cells includes a core, and the shell surrounds the core, wherein the core is at least one of a sacrificial core or a non-sacrificial core, and wherein the woven fabric and the woven fiber are continuously woven on the non-sacrificial core during fabrication of the airfoil.

15. The turbine engine of any one of claims 1-3, wherein, wherein the airfoil is a vane provided within the fan section.

16. An airfoil, characterized by, comprising: an outer wall extending between a leading edge to a trailing edge to define a chordwise direction, and between a root and a tip to define a spanwise direction, the outer wall defining an interior, a pressure side, a suction side, and an arc line extending through the interior between the leading edge and the trailing edge equidistant between the suction side and the pressure side; and at least one cell within the interior and having a shell, the shell comprising: a front portion and a rear portion disposed aft of the front portion relative to the arc line, the front portion and the rear portion connected by a side portion, at least a portion of at least one of the front portion or the rear portion defined by a contour extending in the spanwise direction, the contour having at least one of a linear, non-linear, or wavy contour; and a woven fabric having first fibers extending along a first bias and second fibers extending along a second bias different than the first bias, the woven fabric provided along the front portion, the rear portion, and the side portion.

17. The airfoil of Claim 16, wherein, further comprising a plurality of spaced apart cells having the at least one cell, wherein each cell of the plurality of spaced apart cells is axially spaced apart from each other relative to the arc line.

18. The airfoil of Claim 17, wherein, wherein each cell of the plurality of spaced apart cells includes a respective woven fabric having a respective first bias and a respective woven fiber woven into the respective woven fabric, the respective woven fiber having a respective second bias, and wherein at least one of the first bias or the second bias of one cell of the plurality of spaced apart cells is different or the same, respectively, than the first bias or the second bias of another cell of the plurality of spaced apart cells.

19. A method of forming an airfoil, characterized by, the method comprising: providing an outer wall of the airfoil, the outer wall extending between a leading edge to a trailing edge to define a chordwise direction, and between a root and a tip to define a spanwise direction, the outer wall defining an interior, a pressure side, a suction side, and an arc line extending through the interior between the leading edge and the trailing edge equidistant between the suction side and the pressure side, and providing a shell by: weaving a first woven fabric over an entirety of a first core, the first woven fabric having first fibers extending along a first bias and second fibers extending along a second bias different than the first bias; providing a first portion, a second portion, and an opposing wall at least partially from the first woven fabric, the first portion and the second portion interconnecting respective portions of the opposing wall; providing a profile extending in the chord-wise direction for at least one of the first portion or the second portion, the profile forming at least one of a non-linear or V-shaped profile; and weaving a first woven fabric over a portion of the first core, the first woven fabric having first fibers extending along a first bias and second fibers extending along a second bias different than the first bias; enclosing at least a portion of a cell defined by the first core, the first woven fabric, and the first woven fibers within the interior.

20. The method of claim 19, wherein, further comprising: weaving a second woven fabric over the entire second core, the second woven fabric having third fibers extending along a fourth bias and fourth fibers extending along a fifth bias different than the fourth bias; weaving a second woven fabric over a portion of the second core, the second woven fabric having third fibers extending along a fourth bias and fourth fibers extending along a fifth bias different than the fourth bias; and positioning the second core adjacent to the first core.

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