Aeroshell preform comprising a fibrous web having two deployable portions

Abstract

The present invention relates to a fibrous web (500) extending between a proximal edge (103) and a distal edge (104), between a first side edge (103) and a second side edge (104), and between an inner face (F int ) and an outer face (F ext ), the fibrous web comprising a distal portion (Pdist) located in a longitudinal direction between a middle portion (PI2) and the distal edge, the distal portion comprising in its thickness direction an inner portion (PD int ) and an outer portion (PD ext ), the fibrous web being characterized in that the outer portion is connected with the inner portion by at least one connecting portion (419), the outer portion comprising a first unfoldable portion separated from the inner portion by a first non-interconnected area (421), and a second unfoldable portion separated from the inner portion by a second non-interconnected area (422).

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a fiber web, which can be used, in particular but not exclusively, as a fiber reinforcement for forming an aero-engine fan housing made of composite materials. Background Technology

[0002] The manufacture of composite material covers begins with the production of a strip fiber web, which is made by three-dimensional weaving between multiple layers of warp and weft yarns. The resulting fiber web is wound multiple times on a mold or tooling having the shape of the cover to be produced and held between the mold and the section forming the mold pair to obtain a fiber preform.

[0003] Once the fiber preform is made, that is, after the fiber web is wound, the tooling carrying the fiber preform is closed by a die and then transported to an oven or furnace, where the preform is densified by a matrix, which can be obtained, in particular, by injecting resin into the fiber preform and polymerizing the resin.

[0004] The casing must have a retaining function to contain debris sucked into the engine or blades or blade fragments ejected by centrifugal force, in order to prevent them from completely passing through the casing and releasing high-energy debris.

[0005] Furthermore, the turbine casing is subject to significant vibrational excitation. More specifically, the casing houses blades that experience intense dynamic excitation due to tip impacts during operation. It is crucial that the casing can withstand these dynamic excitations, particularly preventing the excitation of the casing's inherent vibrational modes and the resulting interaction between the rotor and stator.

[0006] It must also be considered that the vibration stress and its natural modes of vibration of the enclosure will change with the wear of the turbine. For safety reasons, it is crucial that the most energetic natural modes of the enclosure are not excited at any time throughout the entire service life of the enclosure.

[0007] To this end, reinforced areas can be set up to ensure that the enclosure has sufficient mechanical strength.

[0008] However, when the enclosure is made of composite materials, adding such reinforcing areas requires attaching the material to the composite structure, which is not easily achieved using current methods.

[0009] Therefore, it is still necessary to strengthen the covers that are not as mechanically strong as those of existing technologies, and it is necessary to obtain these covers in a simpler way than those of existing technologies. Summary of the Invention

[0010] The present invention aims to solve the above-mentioned problems.

[0011] Therefore, the present invention relates to a fiber web that is strip-shaped and extends a defined length in the longitudinal direction between a proximal edge and a distal edge, extends a defined width in the transverse direction between a first side edge and a second side edge, and extends along the thickness between an inner surface and an outer surface.

[0012] The fiber web has a three-dimensional or multi-layered woven structure between multiple warp yarns or plies extending along the longitudinal direction and multiple weft yarns or plies extending along the transverse direction, the fiber web including a distal end located between the middle portion and the distal edge in the longitudinal direction.

[0013] The distal end portion includes an interior and an exterior in its thickness direction, and is configured such that the interior extends between the inner surface and the exterior, and the exterior extends between the interior and the outer surface.

[0014] The fiber web is characterized in that the outer part is connected to the inner part by at least one connecting portion, the outer part including a first deployable portion and a second deployable portion extending from the connecting portion along the transverse direction to a defined width, the first deployable portion being separated from the inner part by a first non-interconnected region, and the second deployable portion being separated from the inner part by a second non-interconnected region.

[0015] The fiber web according to the invention, particularly its two deployable portions, can form a cover preform, which includes a reinforcing member located on the outer surface of the cover preform, and the cover preform can be formed directly from the fiber web.

[0016] This makes it possible to obtain a cover with improved mechanical properties relative to vibration stress, and avoids any steps of adding connecting reinforcements during the cover manufacturing process.

[0017] Furthermore, the reinforcement connects better to the rest of the enclosure because it forms an integral part of the enclosure, requiring no additional attachments or adhesives. In this case, it is referred to as an integral reinforcement.

[0018] In one embodiment, the ratio of the thickness of the outer layer to the thickness of the inner layer is between 150% and 260%.

[0019] In one embodiment, the ratio of the thickness of the outer layer to the thickness of the inner layer is between 160% and 260%.

[0020] In one embodiment, the ratio of the distance from the first side edge to the connection portion to the distance from the second side edge to the connection portion is between 10% and 40%.

[0021] This embodiment ensures that the reinforcement formed by the folding of the deployable portion is located at a certain position on the fiber web and eventually on the cover, which makes it possible to increase the stiffness-to-mass ratio of the cover, thereby increasing the natural frequency that can be obtained within the engine's operating range.

[0022] In one embodiment, the connecting portion is obtained by sewing the outer portion onto the inner portion, by weaving the inner and outer portions together, or by needle-punching the outer portion onto the inner portion.

[0023] Connectors are essential for achieving textile connections between the external and internal parts. Connectors exist between non-interconnected parts.

[0024] All the textile joining methods considered can achieve this connection, and each method offers different advantages.

[0025] The connection obtained by stitching allows the outer portion to be added as excess thickness to the distal end of the rest of the fiber web.

[0026] This allows for very precise selection of external properties and very precise positioning of connecting and non-interconnected areas.

[0027] The joints obtained through co-weaving ensure a very strong attachment between the exterior and interior. Furthermore, this allows the fiber web to be obtained without additional steps, as the joints are formed directly during the weaving process of the fiber web.

[0028] Obtaining the connection through needle punching represents a less complex external connection step compared to the sewing step, and also does not require modification of the weaving steps relative to existing techniques.

[0029] In one embodiment, the distal end includes a plurality of connecting portions that connect the exterior and interior.

[0030] In one embodiment, the distal end includes an upstream region, a middle region, and a downstream region in the width direction, and is configured such that the upstream region extends between the first side edge and the middle region, the middle region extends between the upstream region and the downstream region, and the downstream region extends between the middle region and the second side edge, the middle region including all the connecting portions, and wherein the middle region includes weft yarns and / or warp yarns with properties different from other yarns in the fiber web.

[0031] This embodiment enables the selection of yarns with different properties for the unfoldable regions intended to form a fiber web, thereby optimizing the specific properties of that characteristic region of the fiber web.

[0032] In one embodiment, the yarns outside the middle region have different properties, while the remaining yarns at the distal end are the same as those in the rest of the fiber web.

[0033] In one embodiment, the yarn of the fiber web is selected from yarns having an intermediate modulus (e.g., 300 GPa, such as HexTow sold by HEXCEL). IM7 type carbon fiber) carbon fiber bundles, and said intermediate region includes high modulus (450 GPa, such as HexTow sold by HEXCEL) carbon fiber bundles. The weft and / or warp yarns are made of HM63 type carbon fiber. In this embodiment, the stiffness of the reinforcement is thus maximized. More specifically, since the stiffness of a beam is a function of Young's modulus, cross-section, and length, increasing the modulus is equivalent to increasing the stiffness. This pushes the natural frequency to higher frequencies because it is a function of stiffness divided by mass, while the mass remains constant.

[0034] In one embodiment, the inner and outer parts are not interconnected over a distance of 90% to 98% of the fiber web width.

[0035] This embodiment enables the availability of a sufficiently long deployable portion to ensure further enhanced functionality.

[0036] In one embodiment, the width of the first deployable portion and the second deployable portion extending from the connecting portion along the lateral direction is 1% to 5% of the width of the fiber web.

[0037] The above is a description of the distal end of the fiber web.

[0038] In one embodiment, additional properties can be imparted to the fiber web by adjusting the proximal end of the web.

[0039] In one embodiment, the fiber web includes a proximal end located in the longitudinal direction between the proximal edge and the intermediate portion.

[0040] The proximal end portion includes a proximal end interior and a proximal end exterior in its thickness direction, and is configured such that the proximal end interior extends between the inner surface and the proximal end exterior, and the proximal end exterior extends between the proximal end interior and the outer surface.

[0041] The proximal exterior is connected to the proximal interior via at least one proximal connecting portion. The proximal exterior includes a first proximal deployable portion and a second proximal deployable portion extending from the proximal connecting portion along the lateral direction to a defined width. The first proximal deployable portion is separated from the proximal interior via a first proximal non-interconnection region, and the second proximal deployable portion is separated from the proximal interior via a second proximal non-interconnection region.

[0042] The fiber web according to the invention, particularly its two proximal unfoldable portions, can form a cover preform, the cover preform including an attachment flange located on the inner surface of the cover preform, and can be formed directly from the cover preform.

[0043] This makes it possible to obtain a housing that is significantly simplified in its connection with other components compared to existing housings.

[0044] Therefore, the connection between the attachment flange and the rest of the enclosure is much better than the metal-composite attachment points of existing enclosures because it is part of the fiber web of the enclosure.

[0045] In one embodiment, the ratio of the thickness of the outer proximal end to the thickness of the inner proximal end is between 50% and 170%.

[0046] In one embodiment, the ratio of the distance from the first side edge to the proximal connector to the distance from the second side edge to the proximal connector is between 10% and 30%.

[0047] This embodiment ensures that the attachment flange formed by folding the proximal deployable portion is located at a position on the fiber web and eventually on the cover, which makes it possible to attach other components to the cover in a simplified manner.

[0048] In one embodiment, the proximal connection is obtained by stitching the interior to the exterior, by weaving the interior and the exterior together, or by piercing the proximal interior onto the proximal exterior.

[0049] Proximal connectors are essential for achieving textile attachment between the proximal interior and proximal exterior. Proximal connectors exist between non-interconnected portions.

[0050] All the textile bonding methods considered can achieve this attachment, and each method offers different advantages.

[0051] The proximal connection obtained by suturing allows for the addition of excess thickness at the proximal end to the remaining portion of the fiber web.

[0052] This allows for very precise selection of the properties of the proximal exterior and very precise positioning of the proximal connector and the proximal non-interconnected region.

[0053] Obtaining the proximal connection through co-weaving ensures a very strong attachment between the proximal interior and the proximal exterior. Furthermore, this allows for the formation of the fiber web without additional steps, as the proximal connection is formed directly during the weaving process of the fiber web.

[0054] The proximal connection obtained by needle punching represents an internal connection step that is less complex than the suturing step, and does not require modification of the weaving steps compared to existing techniques.

[0055] In one embodiment, the proximal end includes a plurality of proximal junctions connecting the proximal interior and the proximal exterior.

[0056] In one embodiment, the proximal end includes a proximal upstream region, a proximal middle region, and a proximal downstream region in the width direction, and is configured such that the proximal upstream region extends between a first side edge and the proximal middle region, the proximal middle region extends between the proximal upstream region and the proximal downstream region, the proximal downstream region extends between the proximal middle region and the second side edge, the proximal middle region includes all proximal connections, and wherein the proximal middle region includes weft yarns and / or warp yarns with properties different from other yarns in the fiber web.

[0057] This embodiment enables the selection of yarns with different properties for the proximal expandable portion of the fiber web intended to form a fiber web, thereby optimizing the specific properties of this characteristic region of the fiber web.

[0058] In one embodiment, the yarns inside the proximal middle region have different properties, while the remaining yarns at the proximal end are the same as those in the rest of the fiber web.

[0059] In one embodiment, the yarn of the fiber web is selected from carbon fibers with an intermediate modulus of approximately 300 GPa, such as HewTow fiber sold by HEXCEL. IM7 fiber, and the proximal middle region includes weft and / or warp yarns made of high-modulus (approximately 450 GPa) carbon fibers, such as HewTow fiber sold by HEXCEL. HM63 fiber. In this embodiment, the stiffness of this region is maximized. By increasing the stiffness of this region, and thus ultimately increasing the stiffness of the attachment flange, its mechanical strength is improved.

[0060] In one embodiment, the proximal inner and outer ends are not interconnected over a distance of 95% to 99% of the fiber web width.

[0061] This embodiment enables the obtaining of a proximal deployable portion of sufficient length to form an attachment flange with the desired mechanical properties.

[0062] In one embodiment, the width of the first and second proximal expandable portions extending laterally from the connecting portion is 2% to 5% of the width of the fiber web.

[0063] According to another aspect of the invention, there is a fiber preform for an aircraft housing comprising one or more turns of a fiber web as described above, wherein the inner surface of the proximal edge of the fiber web is located on one side of the radial inner surface of the preform, and the outer surface of the distal edge of the fiber web is located on one side of the radial outer surface of the preform.

[0064] In one embodiment, the middle portion of the fiber web is chosen to correspond to the starting point of the last loop of the winding just described.

[0065] In this embodiment, the reinforcing member formed by the unfoldable portion of the fiber web exists on the entire outer circumference of the cover.

[0066] According to another aspect of the present invention, a method for manufacturing a composite material aircraft housing is provided, comprising at least the following steps:

[0067] - The fiber preform as described above is placed around the cylindrical core;

[0068] - At least one die is provided on the radially outer portion of the fiber preform, the die comprising at least one first die portion and at least one second die portion, the deployable portion of the fiber web being located between the first die portion and the second die portion;

[0069] - A matrix is ​​formed in the fiber web held between the core and the mold.

[0070] In such an embodiment, the aircraft housing is directly manufactured / formed with reinforcements.

[0071] In other words, there is no need to attach the reinforcement to the cover; the reinforcement is formed directly in the fiber web during the formation of the matrix, or more specifically, in the unfoldable portion of the fiber web.

[0072] In addition, the mold includes a geometry suitable for the deployable portion.

[0073] In embodiments where the fiber web includes multiple connectors, the mating pattern may include more than two parts, such that each reinforcement—i.e., two deployable parts formed by a connector—exists between two different mating pattern parts.

[0074] These different molded sections make it easier to demold from the cover once the base is formed.

[0075] In one embodiment, the matrix is ​​organic, such as an epoxy resin, for example, PR520NRTM resin sold by Solvay S.A.

[0076] According to another aspect of the invention, there is a composite gas turbine housing comprising a fiber reinforcement made of a fiber preform as described above and a matrix for densifying the fiber reinforcement.

[0077] This embodiment allows the reinforcements of the gas turbine housing to be manufactured directly during housing formation, thereby improving the mechanical properties of the housing without the need to add reinforcements to the already formed housing.

[0078] Therefore, the cover according to the present invention is simpler to manufacture than the cover of the prior art, and the reinforcement is more reliably attached to the cover.

[0079] According to another aspect of the invention, there is a gas turbine engine comprising a housing as described above. Attached Figure Description

[0080] Figure 1 The diagram illustrates a loom that can be used to manufacture fiber webs according to the invention.

[0081] Figure 2 This refers to the fiber web in the embodiments of the present invention.

[0082] Figure 3 In this invention, and Figure 2 Fiber webs in different embodiments.

[0083] Figure 4 A schematic cross-sectional view of a fiber web in an embodiment of the present invention is shown.

[0084] Figure 5 The diagram schematically illustrates the unfolding operation of the unfoldable portion of a fiber web according to an embodiment of the present invention.

[0085] Figure 6 schematically shown Figure 2 The fiber web described herein, wherein the deployable portion has been unfolded.

[0086] Figure 7 schematically shown Figure 3 The fiber web described herein, wherein the deployable portion has been unfolded.

[0087] Figure 8 The diagram schematically illustrates the process of obtaining a fiber cover preform from a fiber web.

[0088] Figure 9 Show Figure 8 A specific sectional view.

[0089] Figure 10 The illustration schematically shows the laying of a fiber preform, prepared for impregnation, according to an embodiment of the present invention.

[0090] Figure 11The turbine housing of an embodiment of the present invention is shown schematically.

[0091] Figure 12 A turbine according to an embodiment of the present invention is illustrated schematically.

[0092] Figure 13 A fiber web according to an embodiment of the present invention is shown schematically.

[0093] Figure 14 A fiber web according to an embodiment of the present invention is shown schematically. Detailed Implementation

[0094] The present invention will now be described with reference to the accompanying drawings, which are intended to illustrate certain embodiments of the invention and should not be construed as limiting the invention.

[0095] In particular, the accompanying drawings are not drawn to scale, or even to relative scale, and are only used to illustrate the embodiments described below.

[0096] like Figure 1 As shown, the fiber web is woven in a known manner using a jacquard loom 5, on which bundles of warp yarns or ply yarns 20 are arranged in multiple layers, with the warp yarns connected by weft yarns or ply yarns 30.

[0097] exist Figure 1 In the diagram, weft yarn 30 represents the direction Y in the transverse direction, and warp yarn 20 represents the direction X in the longitudinal direction.

[0098] However, it should be noted that the terms "weft" or "warp" are merely naming conventions, and "weft" can be replaced with "warp" in this document and in the remainder of this application, and vice versa.

[0099] Figure 2 This refers to the fiber web 500 in this embodiment of the invention.

[0100] The fiber web 500 is strip-shaped and extends along the longitudinal direction X for a defined length L between the proximal edge 103 and the distal edge 104. 100 The width l is defined by extending along the lateral direction Y between the first side edge 101 and the second side edge 102. 100 And along the thickness Z on the inner surface F int and outer surface F ext Extending between.

[0101] The fiber web 500 has a three-dimensional or multi-layered woven structure between multiple warp yarns or plies 20 extending in the longitudinal direction X and multiple weft yarns or plies 30 extending in the transverse direction Y. The fiber web 500 includes a distal end P located between the middle portion PI2 and the distal portion 104. dist Distal P dist It includes an internal PD in the Z-direction of its thickness.int and external PD ext Set to enable internal PD int On the inner surface F int and external PD ext Extending between, and external PD ext Internal PD int and outer surface F ext Extending between. The fiber web (sometimes also called mesh) 500 includes internal PDs. int and external PD ext At least two non-interconnected regions 421, 422 between them, and also includes internal PDs int Connect to external PD ext The connection part 419, thereby connecting the external PD ext The non-interconnected portions 441 and 442 form the expandable portion of the fiber web around the connecting portion 419.

[0102] In the illustrated embodiment, the middle portion PI2 begins at the starting point 460 at the distal end.

[0103] In one embodiment, the starting point 460 at the distal end can correspond to the starting point of the last ring of the cover preform, such as when combined Figure 10 Described.

[0104] For ease of description of fiber web 500, Figure 2 A fiber web with only one connecting portion 419 is shown, but it should be understood that this embodiment does not limit the invention.

[0105] Fiber web 500 at the distal end P dist It includes an upstream region 410, a middle region 420 and a downstream region 430, and is configured such that the upstream region 410 extends between the first side edge 101 and the middle region 420, the middle region 420 extends between the upstream region 410 and the downstream region 430, and the downstream region 430 extends between the middle region 420 and the second side edge 102.

[0106] For example, depending on the required axial position of the reinforcement, the width l of the upstream region 410 410 It can be in the width of 500 for fiber web 100 Between 10% and 70%.

[0107] For example, depending on the axial position of the reinforcement and the required height, the width l of the intermediate region 420 420 It can be in the width of 500 for fiber web 100 Between 2% and 10%.

[0108] For example, depending on the required axial position of the reinforcement, the width l of the downstream region 430 430It can be in the width of 500 for fiber web 100 Between 30% and 85%.

[0109] In one embodiment, such as Figure 2 As shown, the width l 410 and l 430 They don't have to be equal.

[0110] Fiber web 500 at the distal end P dist It also includes internal PD. int and external PD ext Located on the inner surface F int One side and outer surface F ext One side, which makes it possible to limit Figure 2 The visible fiber web has six regions: upstream interior 471, upstream exterior 444, middle interior region, middle exterior region, downstream interior 472, and downstream exterior 445.

[0111] The intermediate region 420 itself is divided into smaller regions by the connecting part 419 and two non-interconnected regions 421 and 422.

[0112] Therefore, the intermediate region 420 includes an inner portion 453 and two inner portions 451 and 452, which are connected to the outer portion 443 by a connecting portion 419. The two inner portions 451 and 452 are not interconnected with the outer portions 441 and 442 located directly above them, and are separated from the outer portions 441 and 442 by non-interconnected regions 421 and 422.

[0113] In the case of three-dimensional or multi-layer weaving as described herein, when no weft or warp yarns form a textile connection between two non-interconnected parts, one part is referred to as "non-interconnected" with the other, even if the two parts were previously connected together; in other words, the non-interconnected area is formed during weaving. Therefore, the two parts are said to be separated / divided by the non-interconnected area.

[0114] In this invention, under normal circumstances, when there is no textile connection between two components, in other words, when one of the two components is added after weaving, one component is also referred to as "non-interconnected" with the other component. If a portion of the added component is connected to the other component at the connection area by, for example, needle punching, the remaining portion of the added component (outside the connection area) will be referred to as non-interconnected with the other component.

[0115] Part 451 is separated from part 441 by non-interconnected region 421, and part 452 is separated from part 442 by non-interconnected region 422.

[0116] In one embodiment, the non-interconnected region 421 may extend beyond the intermediate region 420, for example, as shown below. Figure 2 As shown, up to the first outer edge 101.

[0117] In one embodiment, upstream inner 471 and upstream outer 444 are not interconnected via non-interconnected region 415 extending from non-interconnected region 421.

[0118] In one embodiment, the non-interconnected region 422 may extend beyond the intermediate region 420, for example, as shown below. Figure 2 As shown, up to the second outer edge 102.

[0119] In one embodiment, the downstream interior 472 and the downstream exterior 445 are not interconnected via a non-interconnected region 417 extending from the non-interconnected region 422.

[0120] In one embodiment, the non-interconnected regions 421 and 422 thus define expandable portions 442 and 441.

[0121] Figure 2 It also includes the corresponding to will Figure 4 The cross-section shown is frame IV.

[0122] exist Figure 2 In the described embodiment, the external PD ext Located within the thickness of the fiber web, in other words, the fiber web 500 at its distal end P dist There is no change in thickness at the starting point of 460.

[0123] In one embodiment, the outer thickness e Dext It can be used in fiber webs with a total thickness of 500 e 100 Between 60% and 72%.

[0124] Figure 3 An alternative embodiment of the fiber web 500 is shown.

[0125] Figure 3 and Figure 2 Similarly, the difference lies in the distal P dist Internal PD int It is an extension of the rest of the fiber web. In other words, the external PD ext For internal PD int Excess thickness, and internal PD int The thickness is equal to the thickness e of the remaining portion of the 500 fiber web. 100 In other words, internal PD int The thickness is equal to the thickness of the portion of the fiber web that extends between the proximal edge 103 and point 460.

[0126] In this embodiment, the outer thickness eDext The total thickness of the fiber web can be 500 e 100 Between 150% and 260%.

[0127] In one embodiment, the thickness of the fiber web 500 can gradually vary from the starting point 460 at the distal end, for example, over a length range of 15 cm on both sides of point 460.

[0128] In one embodiment, the distal external PD ext Internal PD added to the distal end int superior.

[0129] For example, external PD ext It is added after the rest of the fiber web is formed and attached to the internal PD via connector 419. int On the other hand, it can be done, for example, by suturing or needle puncture.

[0130] This embodiment enables the avoidance of any complex operations that create non-interconnected areas during weaving, because, in practice, if the external PD... ext Once attached to the fiber web after its formation, it is by definition not interconnected with the fiber web except at the attachment point.

[0131] Furthermore, this allows for the specific selection of the external PD. ext The fibers are made to have properties different from the rest of the fiber web, thereby ensuring, for example, better mechanical properties.

[0132] Figure 4 exist Figure 3 The distal end P is shown in more detail in the sectional view identified by box IV in the figure. dist .

[0133] distal P dist Included Figure 4 External PD identified in the middle ext and internal PD int Between the two inner edges, there are also upstream region 410, intermediate region 420 and downstream region 430.

[0134] Figure 4 It also shows the upstream interior 471, the upstream exterior 444, the intermediate inner region (451, 452 and 453), the intermediate outer region (441, 442 and 443), the downstream interior 472 and the downstream exterior 445.

[0135] Figure 4 It also clearly shows warp 20 and weft 602, 603, and 606.

[0136] exist Figure 4In the diagram, the weft yarns are indicated by multiple numerical reference numerals according to their configuration relative to the warp yarns 20.

[0137] In one embodiment, internal PD int The weft yarn 602 is woven into the internal PD using a three-dimensional weaving method. int 20 warp threads.

[0138] Here, the term "three-dimensional weaving" or "3D weaving" refers to a weaving method in which at least some warp yarns are joined to weft yarns on multiple weft layers, such as "interlocking weaving." The term "interlocking weaving" refers to a type of three-dimensional weaving in which each warp layer combines with multiple weft layers, and all yarns in the same warp row have the same movement in the weaving plane.

[0139] This in particular makes it possible to have the same weft yarn weave as the rest of the fiber web.

[0140] In one embodiment, such as Figure 4 As shown, external PD ext The weft yarn 606 can be non-connected in the upstream outer 444 and the downstream outer 445.

[0141] More specifically, since they are separated from the upstream interior 471 and the downstream interior 472 by non-interconnected regions 415 and 417, and since they do not necessarily form part of the expandable portions 441 and 442, the yarns of the upstream exterior 444 and the downstream exterior 445 are intended to be cut and do not need to be woven.

[0142] For example, cuts 501 and 502 can be formed at the boundary of the intermediate region 420. The result of these cuts will be combined Figure 5 describe, Figure 5 Will be presented Figure 4 A detailed view of the box identified by the symbol V.

[0143] In one embodiment, the external PD of the intermediate region 420 ext Parts 441, 442, and 443 form a three-dimensional weave with the warp yarns.

[0144] This makes it possible to obtain deployable sections 441 and 442 with excellent performance and very good strength.

[0145] also, Figure 4 The weaving details in the intermediate region 420 are shown. In the illustrated embodiment, regions 441 and 442 are not interconnected with regions 451 and 452, respectively, because the non-interconnected regions 421 and 422 are continuous with the non-interconnected regions 415 and 417, respectively.

[0146] More specifically, the weft yarns of the outer middle region 441 (or 442) are not connected to the warp yarns of the inner middle region 451 (or 452).

[0147] Conversely, at the connecting portion 419, the weft yarn of the outer intermediate region 443 is connected to the warp yarn of the inner intermediate region 453. The weave 603 is shown schematically here, but it will be understood that the connecting portion 419 is formed to terminate at the non-interconnected regions 421 and 422.

[0148] Here, the connecting portion 419 is represented as yarn 603 weaving through the connecting portion 419, but the specific effect of the connecting portion 419 formed by the weft yarn of portion 443 and the warp yarn of portion 453 can be obtained by other textile methods, especially needle punching or sewing.

[0149] Combination Figure 5 The description details the effect of the connecting part 419.

[0150] Figure 5 This indicates the intermediate region 420. More precisely, it shows the steps for unfolding the deployable parts 441 and 442.

[0151] Because of the non-interconnected regions 421 and 422, the deployable portions 441 and 442 can be deployed around the connecting portion 419. Therefore, a fiber web with a more complex geometry than the initial fiber web is formed.

[0152] Figure 5 The expandable portions 441 and 442 are shown after the cuts 501 and 502 are formed.

[0153] In one embodiment, the length of the deployable portion is selected based on the reinforcing properties desired for the intended use of the fiber web.

[0154] For example, if the fiber mesh is intended to form an aerospace shroud preform, the length of the deployable portion can be between 1.8×π×R and 2.2×π×R, where R is the radius of the outer skin of the shroud.

[0155] In other words, the length of the deployable section can be between 90% and 110% of the length of the outer skin of the cover.

[0156] Cuts 501 and 502 thus mark the ends of the expandable portions 441 and 442. For example, cuts 501 and 502 are at the distal end P. dist It is formed over its entire length, and its thickness corresponds to that of the outer PD. ext thickness e Dext .

[0157] In other embodiments, particularly when there are more connecting portions, the deployable portion can extend to the first inner edge 101 or the second inner edge 102 without requiring a cut.

[0158] However, other cuts can be formed in the intermediate region 420, between the two connecting parts, to form a deployable part.

[0159] Figure 6 This refers to the fiber web obtained after the cutting and unfolding operations of the unfoldable sections 441 and 442.

[0160] Figure 6 More precisely, this corresponds to the period after all forming operations of the deployable sections 441 and 442. Figure 2 Medium fiber mesh.

[0161] In particular, it will be noted that at the distal end P of the fiber web dist At the starting point 460, a decrease in thickness of 461 was observed.

[0162] More specifically, relative to the initial fiber web, i.e. Figure 2 The fiber web, with upstream outer section 444 and downstream outer section 445 removed.

[0163] Because these portions are included in the distal end P of the fiber web dist The thickness, therefore, once the upstream outer 444 and downstream outer 445 are removed, the distal end P dist The thickness decreases.

[0164] Therefore, after the deployable portion unfolds, the distal end P dist Only the internal PD consisting of the aforementioned regions 471, 451, 453, 452, and 472 is included. int .

[0165] In one embodiment, the deployable portions 441 and 442 together form the reinforcing member 480.

[0166] The reinforcing member 480 is held on the assembly of the rest of the fiber web by means of the connecting part 419.

[0167] The rest of the fiber web is the same as described above.

[0168] exist Figure 7 In the alternative embodiment shown, the reinforcement 480 can be formed such that the distal end P is not reduced. dist The thickness of the fiber web at the starting point 460.

[0169] In this situation, the internal PD of the fiber web int It has a similar thickness to the rest of the fiber web, such as, for example Figure 3 The embodiment shown has an external PD. ext Added to the internal PD via suturing or needle puncture. int superior.

[0170] In any case, the unfolding of the deployable parts 441 and 442 can form the reinforcing member 480.

[0171] Figure 8 The steps of setting the fiber web 500 as described above on the mold 50 to form a turbine housing preform are shown.

[0172] The mold 50 may include a core 710 having the shape of the cover to be formed.

[0173] Figure 8 The diagram illustrates a fiber shroud reinforcement formed by winding the aforementioned fiber web 500 onto a mold 50. This fiber reinforcement constitutes a complete tubular fiber preform of the shroud, forming a single piece. In particular, the distal ends of the fiber web 500 are visible here laid on the core 710.

[0174] The mold 50 includes a core 710, which has an outer surface 51 whose contour corresponds to the inner surface of the cover to be produced.

[0175] The inner surface F of fiber web 500 int It is placed on the outer surface 51 of the core 710, and then the fiber web 500 is wound from its proximal edge 103 to its distal edge 104.

[0176] exist Figure 8 In the diagram, the two arrows indicate the rotation of the core 710 required to form the fiber web. Of course, the fiber web can also be laid with the core fixed.

[0177] The core 710 also includes two flanges 52 and 53 for forming the ends of the fiber preforms corresponding to the flanges of the cover, namely the downstream flange 62 and the upstream flange 63.

[0178] The portions of the fiber preform corresponding to the cover flanges 62 and 63 terminate at the second side edge 102 and the first side edge 101, respectively.

[0179] Figure 9 Indicates by Figure 8 Box IX shows a cross-section of the fiber web laid on the mold 50.

[0180] The mold 50 includes a core 710, and also includes a first mold pair 721 and a second mold pair 722.

[0181] Figure 9 The illustration shows a specific case of a fiber web having only one connector 419 and therefore only one reinforcement 480, but it should be understood that fiber webs having multiple connectors and therefore multiple reinforcements can be handled in a similar manner.

[0182] exist Figure 9In the illustrated embodiment, the first mold portion 721 may be formed as a cover portion extending between the first side edge 101 and the reinforcement 480, while the second mold portion 722 may be formed as a cover portion extending between the reinforcement 480 and the second side edge 102.

[0183] Furthermore, dividing the mold into two parts 721 and 722 ensures easy demolding without the risk of damaging the reinforcing member 480.

[0184] Figure 10 The image shows the fiber web 500 wrapped around the core 710 from another angle.

[0185] The fiber web 500 begins to wrap around the core from its proximal edge 103, and the inner surface F of the fiber web int It is disposed on the outer surface 51 of the core 710. Winding results in multiple turns of the fiber web to form a preform, up to the distal end P. dist The laying, such as Figure 10 As shown.

[0186] In the illustrated embodiment, the distal end P dist Starting from point 460, this point indicates the starting point of the last loop of the fiber web on core 710.

[0187] This embodiment ensures that the distal end P of the fiber web 500 dist The reinforcing member 480 formed by the expandable parts 441 and 442 exists on the entire last ring and ultimately on the entire circumference of the cover.

[0188] In an alternative embodiment, it may be preferable to have the reinforcement 480 only on a portion of the circumference of the cover, for which it would be sufficient to set point 460 closer to the distal edge 104.

[0189] Figure 10 The core 710 shown also has a counterpart mold 721.

[0190] In this case, the die 721 includes multiple die segments (all labeled 721) and together form the die 721 for the entire circumference of the core 710.

[0191] For example, once the fiber web 500 is placed on the core 710 to form a turbine housing fiber preform, the preform can then be densified by the matrix.

[0192] Densification of fiber preforms involves filling all or part of the pores in the preform with the material that constitutes the matrix.

[0193] The matrix can be obtained using liquid methods known per se. Liquid methods involve impregnating a preform with a liquid composition containing an organic precursor of the matrix material. The organic precursor is typically in the form of a polymer, such as a resin, optionally diluted in a solvent. The fiber preform is placed in a mold (the mold having recesses for molding the final part shape), which can be sealed shut. Figure 10 As shown, here the fiber preform is placed between multiple segments 721 and 722 forming the mold and the core 710 forming the support, these elements having the outer and inner shapes of the cover to be produced, respectively. Then, a matrix precursor liquid, such as resin, is injected into the entire recess to impregnate the preform.

[0194] The conversion of the precursor to the organic matrix, i.e., its polymerization, is carried out by heat treatment (usually by heating the mold). After all the solvents are removed and the polymer is cross-linked, the preform remains in the mold and has the shape corresponding to the part to be produced. The organic matrix can be obtained, in particular, from epoxy resins, such as commercially available high-performance epoxy resins, or from liquid precursors of carbon or ceramic matrices.

[0195] In the case of forming a carbon or ceramic matrix, heat treatment involves pyrolyzing an organic precursor to convert the organic matrix into a carbon or ceramic matrix, depending on the precursor used and the pyrolysis conditions. For example, the carbon liquid precursor can be a resin with a relatively high carbon content, such as a phenolic resin, while the ceramic liquid precursor, particularly a SiC precursor, can be a polycarbosilane (PCS), polytitanium carbosilane (PTCS), or polysilazane (PSZ) resin. Several consecutive cycles from impregnation to heat treatment can be performed to achieve the desired degree of densification.

[0196] Densification of fiber preforms can be achieved using a well-known resin transfer molding (RTM) method. In the RTM method, the fiber preform is placed in a mold having the shape of the housing to be produced. A thermosetting resin is injected into an internal space defined by a rigid material component and the mold, which includes the fiber preform. Within this internal space, a pressure gradient is typically established between the resin injection point and the resin discharge orifice to control and optimize resin impregnation of the preform.

[0197] The resin used can be, for example, epoxy resin. Resins suitable for the RTM method are well known. They preferably have low viscosity to facilitate their incorporation into the fibers. The choice of the resin's temperature rating and / or chemical properties is determined based on the thermomechanical stresses the component must withstand. Once the resin is infused throughout the reinforcement, its polymerization is carried out by heat treatment according to the RTM method.

[0198] After injection and polymerization, the part is demolded. Finally, the part is trimmed to remove excess resin and chamfered to achieve the desired finish. Figure 11The cover shown is 1010.

[0199] The housing 1010 is the housing for the fan of an aviation gas turbine engine. The housing also includes a reinforcing member 480 formed by densification of the aforementioned deployable portions 441 and 442.

[0200] In addition, the cover includes an upstream flange 1001 and a downstream flange 1002 formed by the aforementioned fiber preform portions 62 and 63.

[0201] Figure 12 An aircraft engine including the housing 1010 as described above is shown.

[0202] like Figure 12 This type of engine, schematically shown at a medium height, includes, from upstream to downstream in the airflow direction: a fan 81 located at the engine intake, a compressor 82, a combustion chamber 83, a high-pressure turbine 84, and a low-pressure turbine 85. The engine is housed within a casing and includes multiple sections corresponding to the various engine components. Therefore, the fan 81 is surrounded by the casing 1010. Furthermore, as... Figure 12 As shown, the cover 1010 includes a reinforcing member 480.

[0203] The above description pertains to the distal end P of the fiber web. dist of.

[0204] In a particular embodiment of the invention, the fiber web used in the invention may include a specific proximal end that may form a flange directly on the inside of the cover during cover manufacturing.

[0205] The following describes specific embodiments of the proximal end of the fiber web, which can be combined independently with the embodiments of the distal end described above.

[0206] Figure 13 Such an embodiment is shown.

[0207] Figure 13 The fiber web 900 is shown, with its proximal and distal ends including non-interconnected regions, but located on opposite surfaces.

[0208] As described above, the fiber web can then be formed into a turbine housing, which includes one or more attachment flanges on its inner circumferential surface and one or more reinforcements on its outer surface.

[0209] therefore, Figure 13 The distal end P is shown as described above. dist Its expandable part is on the outer surface F ext A reinforcing member 480 is formed on top.

[0210] Symmetrically, the proximal end P of the fiber web proxIncludes flange 180, flange 180 being formed at the proximal end P prox Inner surface F int One or more expandable proximal ends are formed on the surface.

[0211] The proximal end extends between the intermediate region PI1 and the proximal edge 103.

[0212] Figure 14 The following diagram illustrates the implementation. Figure 13 The specific proximal end of the fiber web.

[0213] The following description pertains only to the proximal portion used to implement the fiber web. Due to symmetry, if the terms used for the distal portion above are reused without the adjectives "proximal" or "distal," it should be understood that the following description pertains to the proximal portion.

[0214] Figure 14 Only the proximal P is shown prox However, it should be understood that, for clear reasons, Figure 14 The distal portion not specifically specified in the text conforms to the distal portion as described above, for example, in combination with... Figure 2 or Figure 3 The far end of the description.

[0215] exist Figure 14 In the middle, the fiber web is strip-shaped and extends along the longitudinal direction X between the proximal portion 103 and the distal portion 104 for a defined length L. 100 The width l is defined by extending along the lateral direction Y between the first side edge 101 and the second side edge 102. 100 And along the thickness Z on the inner surface F int and outer surface F ext Extending between.

[0216] The fiber web has a three-dimensional or multi-layered woven structure between multiple warp yarns or plies 20 extending in the longitudinal direction X and multiple weft yarns or plies 30 extending in the transverse direction Y. The fiber web includes a proximal end P located between the middle portion PI1 and the proximal end portion 103. prox Proximal P prox In the Z-direction of its thickness, including the proximal inner PP int and proximal external PP ext The proximal P prox Set to enable proximal internal PP int On the inner surface F int and proximal external PP ext Extending between, and the proximal external PP ext PP in the proximal end int and outer surface F ext Extending between. The fiber web includes PP inside the proximal end. intand proximal external PP ext At least two proximal non-interconnected regions 121, 122 between them, and it also includes a proximal internal PP. int Connect to the proximal external PP ext The proximal connection portion 119, thereby the proximal internal PP int The non-interconnected portions 141 and 142 form the expandable proximal end of the fiber web around the proximal end connector 119.

[0217] In the illustrated embodiment, the intermediate portion PI1 extends from the proximal end P prox The endpoint starts at 160.

[0218] In one embodiment, point 160 may correspond to, for example: Figure 10 The end point of the first ring of the preform of the cover body shown.

[0219] For ease of description of fiber webs, Figure 14 The illustration shows a fiber web with only the proximal connection portion 119, but it should be understood that this embodiment is not limiting.

[0220] Fiber web near end P dist The fiber web includes a proximal upstream region 110, a proximal intermediate region 120, and a proximal downstream region 130. The fiber web is configured such that the proximal upstream region 110 extends between a first side edge 101 and the proximal intermediate region 120, the proximal intermediate region 120 extends between the proximal upstream region 110 and the proximal downstream region 130, and the downstream region 130 extends between the proximal intermediate region 120 and the second side edge 102.

[0221] For example, the width l of the upstream region 110 at the proximal end 110 The width of the fiber web can be l 100 The percentage ranges from 5% to 90%, depending on the required axial position of the attachment flange.

[0222] For example, the width l of the proximal intermediate region 120 120 The width of the fiber web can be l 100 It is between 2% and 10%, depending on the required axial position of the attachment flange.

[0223] For example, the width l of the proximal downstream region 130 130 The width of the fiber web can be l 100 The percentage ranges from 5% to 90%, depending on the required axial position of the attachment flange.

[0224] In particular, such as Figure 14 As shown, the width l 110 and l 130 They don't have to be equal.

[0225] Fiber web near end P prox It also includes the proximal internal PP int and proximal external PP ext This makes it possible to limit Figure 2 The visible fiber web consists of six regions: upstream proximal outer region 171, upstream proximal inner region 144, mid-proximal inner region, mid-proximal outer region, downstream proximal outer region 172, and downstream proximal inner region 145.

[0226] The proximal intermediate region 120 itself is divided into a proximal connecting portion 119 and two proximal non-interconnecting regions 121 and 122.

[0227] Therefore, the proximal intermediate region 120 includes a proximal outer portion 153 and two proximal outer portions 151 and 152, the proximal outer portion 153 being connected to the proximal inner portion 143 via a proximal connection portion 119, and the two proximal outer portions 151 and 152 being non-interconnected with the proximal inner portions 141 and 142 located directly below.

[0228] Part 151 is separated from the proximal part 141 by non-interconnection region 121, and part 152 is separated from part 142 by non-interconnection region 122.

[0229] In one embodiment, the non-interconnected region 121 may extend beyond the proximal intermediate region 120, for example, as shown below. Figure 14 As shown, it extends to the first outer edge 101.

[0230] In one embodiment, the proximal upstream outer 171 and the proximal upstream inner 144 are not interconnected by a non-interconnected region 115 that is continuous with the non-interconnected region 121.

[0231] In one embodiment, the non-interconnected region 122 may extend beyond the proximal intermediate region 420, for example, as shown below. Figure 14 As shown, it extends to the second outer edge 102.

[0232] In one embodiment, the proximal downstream exterior 172 and the proximal downstream interior 145 are not interconnected by a non-interconnected region 117 that is continuous with the non-interconnected region 122.

[0233] In one embodiment, the non-interconnected regions 121 and 122 thus define expandable portions 142 and 141.

[0234] exist Figure 14 In the described embodiment, the proximal internal PP int It is set within the thickness of the fiber web; in other words, the fiber web is located near the end P. prox There was no change in thickness at the endpoint 160.

[0235] In one embodiment, the thickness e inside the proximal end Pint The total thickness e of the fiber web can be 100 Between 30% and 60%.

[0236] In an embodiment not shown, the proximal internal PP int It can be added to fiber mesh.

[0237] The proximal deployable portions 142 and 141 can form the flange 180 in a manner similar to that used to form the reinforcement 480 in the distal deployable portion, such as when combined Figure 4 and Figure 5 As described.

[0238] Such a proximal end may require the above combination Figures 8 to 11 The described impregnation method has been adjusted.

[0239] The following description is of a specific case of a fiber web having only a proximal connector 119 and therefore only one flange 180, but it should be understood that fiber webs having multiple proximal connectors and therefore multiple flanges can be handled in a similar manner.

[0240] Due to the F on the inner surface of the fiber preform int There is a flange 180 on the core, so the core 710 can be divided into two parts.

[0241] In this embodiment, and in a manner similar to splitting the mold into two parts 721 and 722, the first mold part can be formed to form a cover portion extending between the first side edge 101 and the flange 180, while the second mold part can be formed to form a cover portion extending between the flange 180 and the second side edge 102.

[0242] In addition, dividing the mold into two parts ensures easy demolding without the risk of damaging the flange 180.

Claims

1. A fiber preform for an aircraft housing, comprising one or more turns of a fiber web (500) wound together, the fiber web being strip-shaped and extending along a longitudinal direction (X) for a defined length (L) between a proximal edge (103) and a distal edge (104). 100 The width (l) is defined by extending along the lateral direction (Y) between the first side edge (101) and the second side edge (102). 100 ), and along the thickness (Z) on the inner surface (F) int ) and outer surface (F ext Extending between ) The fiber web has a three-dimensional or multi-layered woven structure between multiple warp yarns or plies (20) extending in the longitudinal direction and multiple weft yarns or plies (30) extending in the transverse direction, the fiber web including a distal end portion (P) located between the middle portion (PI2) and the distal edge in the longitudinal direction. dist ), The distal end includes an interior (PD) in its thickness direction. int ) and external (PD) ext And configured such that: the interior extends between the inner surface and the outer surface, and the outer surface extends between the interior and the outer surface. The fiber web is characterized in that the outer portion is connected to the inner portion via at least one connecting portion (419), the outer portion comprising a first deployable portion and a second deployable portion (441, 442) of a defined width extending from the connecting portion along the transverse direction, the first deployable portion being separated from the inner portion by a first non-interconnected region (421), and the second deployable portion being separated from the inner portion by a second non-interconnected region (422). The inner surface (F) of the proximal edge (103) of the fiber web int The outer surface (F) of the distal edge (104) of the fiber web is located on one side of the radial inner surface of the preform and on the outer surface of the fiber web. ext It is located on one side of the radial outer surface of the preform.

2. The aircraft housing fiber preform according to claim 1, wherein, The thickness of the outer part (e) Dext The ratio of the thickness of the interior to the thickness of the interior is between 160% and 260%.

3. The aircraft housing fiber preform according to claim 1 or 2, wherein, The ratio of the distance from the first side edge (101) to the connecting portion (419) to the distance from the second side edge (102) to the connecting portion is between 10% and 40%.

4. The aircraft housing fiber preform according to claim 1 or 2, wherein, The connecting portion (419) is obtained by sewing the outer part onto the inner part, by weaving the inner and outer parts together, or by piercing the outer part onto the inner part.

5. The aerospace housing fiber preform according to claim 1 or 2, wherein, The distal end includes an upstream region (410), a middle region (420), and a downstream region (430) in the width direction, and is configured such that: the upstream region extends between the first side edge and the middle region, the middle region extends between the upstream region and the downstream region, and the downstream region extends between the middle region and the second side edge, the middle region includes all of the connecting portions (419), and wherein the middle region includes weft yarns and / or warp yarns that have different properties from the other yarns of the fiber web.

6. The aircraft housing fiber preform according to claim 5, wherein, The yarns of the fiber web are selected from carbon fiber bundles with intermediate modulus, and the intermediate region includes high-modulus carbon fiber weft yarns and / or warp yarns.

7. The aerospace housing fiber preform according to claim 1 or 2, wherein, The width of the first deployable portion and the second deployable portion (441, 442) extending from the connecting portion (419) in the transverse direction is 1% to 5% of the width of the fiber web.

8. The aerospace housing fiber preform according to claim 1 or 2, wherein, The fiber web also includes a proximal end (P) located in the longitudinal direction between the proximal edge (103) and the middle portion (PI1). prox ), The proximal end portion includes a proximal end interior and a proximal end exterior in its thickness direction, and is configured such that: the proximal end interior (PP) int ) on the inner surface (F int ) and the proximal exterior (PP) ext Extending between the proximal end and the outer surface (F), and the proximal end exterior extends between the proximal end interior and the outer surface (F). ext Extending between ) The proximal exterior is connected to the proximal interior via at least one proximal connector (119). The proximal exterior includes a first proximal deployable portion and a second proximal deployable portion (141, 142) with a width defined by extending from the proximal connector along the lateral direction. The first proximal deployable portion (141) is separated from the proximal interior via a first proximal non-interconnection region (121), and the second proximal deployable portion (142) is separated from the proximal interior via a second proximal non-interconnection region (122).

9. The aerospace housing fiber preform according to claim 6, wherein, The intermediate modulus is 300 GPa.

10. The aerospace housing fiber preform according to claim 6, wherein, The high modulus is 450 GPa.

11. A method for manufacturing a composite material aircraft housing (1010), characterized in that, At least the following steps are included: - The fiber preform according to claim 1 is disposed around the cylindrical core (710); - At least one die is provided on the radially outer portion of the fiber preform, the die comprising at least one first die portion (721) and at least one second die portion (722), and the deployable portion (441, 442) of the fiber web (500) is located between the first die portion and the second die portion; - A matrix is ​​formed in the fiber web held between the core and the mold.

12. A composite material gas turbine housing (1010), characterized in that, It includes a fiber reinforcement composed of a fiber preform according to claim 1 and a matrix for densifying the fiber reinforcement.

13. An aviation gas turbine engine (80), characterized in that, Includes the cover (1010) according to claim 12.

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