Preform for making casing structure for turbine engine

Abstract

A preform for making a casing structure for a turbine engine. The preform includes a plurality of reinforcing fiber bundles arranged in a two-dimensional woven structure, a three-dimensional woven structure, or a braided structure. The plurality of reinforcing fiber bundles include unitary woven or woven fiber bundles having a diameter or density greater than a corresponding diameter or density of other woven or woven fiber bundles in a two-dimensional woven structure, a three-dimensional woven structure, or a woven structure. The unitary woven or woven fiber bundle is located in the region of the preform that is bent to form the angular corner, thereby providing strength to the shell structure that includes the angular corner.

Description

[0001] Government licensing rights

[0002] This invention was made with U.S. Government support. The U.S. Government may have certain rights in this invention. Technical Field

[0003] The present disclosure relates generally to casing structures in turbine engines, and particularly to preforms for making casing structures for turbine engines. Background Art

[0004] Turbine engines, such as gas turbine engines, typically include a fan and a turbocharger. A casing structure houses various components of the turbine engine, such as a fan casing for the fan. Each casing structure may have a flange for coupling to another casing structure. The flange may be integrally formed with the casing structure. The flanges on the casing structures typically have angled corners (e.g., square corners). BRIEF DESCRIPTION OF THE DRAWINGS

[0005] Features and advantages will be apparent from the following more particular description of various exemplary embodiments, as illustrated in the accompanying drawings, in which like reference numbers generally indicate identical, functionally similar, and / or structurally similar elements.

[0006] Figure 1 is a schematic cross-sectional view of a turbine engine according to aspects of the present disclosure.

[0007] Figure 2 is a cross-sectional view of two flanges of a housing structure coupled to each other according to an embodiment of the present disclosure.

[0008] Figure 3A is a schematic representation of a portion of a first housing structure prior to forming a first flange according to an embodiment of the present disclosure.

[0009] Figure 3B is a schematic cross-section of a region of a three-dimensional woven preform used in a first angular corner of a first flange of a first shell structure according to an embodiment of the present disclosure.

[0010] Figure 3C is a schematic representation of a portion of a first housing structure after forming a first flange according to an embodiment of the present disclosure.

[0011] Figure 4A is a schematic diagram of a three-dimensional fiber weaving pattern according to an embodiment of the present disclosure.

[0012] Figure 4B According to the embodiment of the present disclosure Figure 4A The line 4B-4B in the Figure 4ASchematic cross-sectional view of the fiber weave pattern shown in .

[0013] Figure 4C is a schematic cross-sectional view of a fiber weave pattern according to another embodiment of the present disclosure, which is shown with Figure 4A The fiber weave pattern shown in is similar, but has a different interlocking fiber pattern.

[0014] Figure 4D is a schematic cross-sectional view of a fiber weave pattern according to another embodiment of the present disclosure, which is shown with Figure 4A The fiber weave pattern shown in is similar, but has another interlocking fiber pattern.

[0015] Figure 5 According to an embodiment of the present disclosure, a method for manufacturing a Figure 2 A flow chart of the general process for composite components of shell structures is shown in FIG. DETAILED DESCRIPTION

[0016] Features, advantages, and embodiments of the present disclosure are set forth or apparent by considering the following detailed description, drawings, and claims.Also, the following detailed description is exemplary and is intended to provide further explanation without limiting the claimed disclosure.

[0017] Various embodiments of the present disclosure are discussed in detail below. Although specific embodiments are discussed, this is for illustrative purposes only. Those skilled in the relevant art will recognize that other components and configurations may be used without departing from the present disclosure.

[0018] The terms "upstream" and "downstream" refer to relative directions relative to the flow of a fluid in a fluid path. For example, "upstream" refers to the direction from which the fluid is flowing, while "downstream" is the direction toward which the fluid is flowing.

[0019] The singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0020] As used herein, the terms "axial" and "axially" refer to directions and orientations extending substantially parallel to the centerline axis of a turbine engine. Furthermore, the terms "radial" and "radially" refer to directions and orientations extending substantially perpendicular to the centerline axis of a turbine engine. Furthermore, as used herein, the terms "circumferential" and "circumferentially" refer to directions and orientations extending arcuately about the centerline axis of a turbine engine.

[0021] As used herein, the terms "first," "second," and "third," etc., may be used interchangeably to distinguish one component from another and are not intended to indicate the position or importance of each component.

[0022] As used herein throughout the specification and claims, approximating language is used to modify any quantitative expression that can be permitted to vary without resulting in a change in the basic function to which it is associated. Thus, a value modified by one or more terms such as "about," "approximately," and "substantially" is not limited to the precise value specified. In at least some cases, approximate language can correspond to the precision of an instrument used to measure a value, or the precision of a method or machine used to construct or manufacture a component and / or system. For example, approximate language can refer to within a margin of one percent, two percent, four percent, ten percent, fifteen percent, or twenty percent in a single value, a range of values, and / or an endpoint of a range defining a value.

[0023] Here and throughout the specification and claims, range limitations are combined and interchanged. Unless context or language indicates otherwise, such ranges are identified and include all subranges contained therein. For example, all ranges disclosed herein include the endpoints, and the endpoints are independently combinable with each other.

[0024] As used herein, the term "composite material" refers to a material having two or more constituent materials. A composite material can be a combination of at least two or more metals, non-metals, or a combination of metal and non-metal elements or materials. Examples of composite materials can include, but are not limited to, polymer matrix composites (PMCs), ceramic matrix composites (CMCs), and metal matrix composites (MMCs). A composite material can be formed from a matrix material and a reinforcing element, such as fiber (referred to herein as reinforcing fiber).

[0025] As used herein, "reinforcement fibers" or "reinforcement fiber bundles" may include, for example, glass fibers, carbon fibers, steel fibers, or para-aramid fibers, such as those available from DuPont de Nemours and Company, Wilmington, Delaware. The reinforcing fibers may be in the form of a fiber bundle comprising a plurality of fibers forming a bundle. The fiber bundle may comprise hundreds or thousands of fibers, such as 3000 (3k), 12000 (12k), 24000 (24k), etc. The polymer matrix material may comprise, for example, a thermosetting resin, a thermoplastic resin, a bismaleimide (BMI) material, or a polyimide material.

[0026] As used herein, a "preform" is a piece of three-dimensional woven fabric formed from a plurality of reinforcing fiber bundles including warp fiber bundles and weft fiber bundles.

[0027] As used herein, a "composite component" refers to a structure or component comprising any suitable composite material. A composite component, such as a composite airfoil, may comprise multiple layers or plies of composite material. The stiffness, material, and dimensions of these layers or plies may be varied to achieve a desired composite component or composite portion of a component having a predetermined weight, size, stiffness, and strength.

[0028] One or more layers of adhesive may be used to form or join composite parts. Adhesives may include resins and phenolics, where the adhesive may require curing at elevated temperatures or other hardening techniques.

[0029] As used herein, PMC refers to a class of materials. A PMC material can be a prepreg. A prepreg is a reinforcement material (e.g., reinforcing fibers) pre-impregnated with a polymer matrix material (e.g., a thermoplastic resin). The reinforcing fiber bundles are embedded within the polymer matrix material (e.g., a thermoplastic resin). Non-limiting examples of processes for producing thermoplastic prepregs include hot melt prepreg, in which the fiber reinforcement is pulled through a molten bath of resin; and powder prepreg, in which the resin is electrostatically deposited onto the fiber reinforcement, as a non-limiting example, and then adhered to the fibers, as a non-limiting example, in an oven or with the aid of heated rollers.

[0030] The resin of the matrix material for PMC can be generally divided into thermosetting resin polymer or thermoplastic resin polymer.Thermoplastic resin polymer is generally classified as can soften and flow repeatedly when heated, and when fully cooled due to physical change rather than chemical change and hardening polymer.The significant example category of thermoplastic resin polymer includes nylon, thermoplastic polyester, polyaryletherketone and polycarbonate resin.The specific example of the high performance thermoplastic resin considered for aerospace application includes polyetheretherketone (PEEK), polyetherketoneketone (PEKK), polyetherimide (PEI), polyaryletherketone (PAEK) and polyphenylene sulfide (PPS).On the contrary, once fully cured into hard rigid solid, thermosetting resin does not significantly soften when heated, but thermal decomposition occurs when fully heated.The significant example of thermosetting resin polymer includes epoxy resin, bismaleimide (BMI) and polyimide resin.

[0031] Another non-limiting example is not to use a prepreg with a thermoplastic polymer, but to utilize a woven fabric. The woven fabric may include, but is not limited to, dry carbon fibers woven together with thermoplastic polymer fibers or filaments. Non-prepreg braided architectures can be made in a similar manner. Using this method, the fiber volume of a part can be adjusted by specifying the relative concentrations of the thermoplastic fibers and reinforcing fibers that have been woven or braided together. In addition, different types of reinforcing fibers can be woven or woven together in various concentrations to adjust the properties of the part. For example, glass fiber, carbon fiber, and thermoplastic fibers can all be woven together in various concentrations to adjust the properties of the part. Carbon fibers provide the strength of the system, glass fibers can be added to enhance impact performance, a design feature of parts located near the inlet of an engine, and thermoplastic fibers provide bonding for the reinforcing fibers.

[0032] In another non-limiting example, resin transfer molding (RTM) can be used to form at least a portion of a composite component. Typically, RTM involves applying dry fibers to a mold or cavity. The dry fibers can include prepregs, braided materials, woven materials, or any combination thereof. Resin can be pumped into or otherwise provided to the mold or cavity to impregnate the dry fibers. The combination of impregnated fibers and resin is then cured and removed from the mold. When removed from the mold, the composite component may require post-curing. RTM can be a vacuum-assisted process. That is, air can be removed from the cavity or mold and replaced with resin before heating or curing. The placement of the dry fibers can be manual or automatic. The profile of the dry fibers can be designed to shape the composite component or guide the resin. Optionally, additional layers or reinforcement layers of a material different from the dry fibers can also be included or added before heating or curing.

[0033] As used herein, CMC refers to a class of materials having reinforcing fibers in a ceramic matrix. Typically, the reinforcing fibers provide structural integrity to the ceramic matrix. Some examples of reinforcing fibers may include, but are not limited to, non-oxide silicon-based materials (e.g., silicon carbide, silicon nitride, or mixtures thereof), non-oxide carbon-based materials (e.g., carbon), oxide ceramics (e.g., silicon oxycarbide, silicon oxynitride, aluminum oxide (Al2O3), silicon dioxide (SiO2), aluminosilicates (e.g., mullite), or mixtures thereof), or mixtures thereof.

[0034] Some examples of ceramic matrix materials may include, but are not limited to, non-oxide silicon-based materials (e.g., silicon carbide, silicon nitride, or mixtures thereof), oxide ceramics (e.g., silicon oxycarbide, silicon oxynitride, aluminum oxide (Al2O3), silicon dioxide (SiO2), aluminosilicates, or mixtures thereof), or mixtures thereof. Optionally, the ceramic matrix may further include ceramic particles (e.g., oxides of Si, Al, Zr, Y, and combinations thereof) and inorganic fillers (e.g., pyrophyllite, wollastonite, mica, talc, kyanite, and montmorillonite).

[0035] Typically, a specific CMC can be referred to as its fiber type / matrix type combination. For example, C / SiC represents carbon fiber reinforced silicon carbide, SiC / SiC represents silicon carbide fiber reinforced silicon carbide, SiC / SiN represents silicon carbide fiber reinforced silicon nitride, SiC / SiC-SiN represents silicon carbide fiber reinforced silicon carbide / silicon nitride matrix mixture, and so on. In other examples, a CMC can be composed of a matrix and reinforcing fibers, the reinforcing fibers including oxide-based materials such as aluminum oxide (Al2O3), silicon dioxide (SiO2), aluminosilicates, and mixtures thereof. Aluminosilicates can include crystalline materials such as mullite (3A12O3·2S7O2) as well as glassy aluminosilicates.

[0036] In some non-limiting examples, before reinforcing fibers are incorporated into the matrix, they can be bundled (for example, to form a reinforcing fiber bundle) and / or coated. Before forming a preform or after forming a preform, the bundle of reinforcing fibers (that is, a reinforcing fiber bundle) can be impregnated with a slurry composition. Then, the preform can be heat-treated and then chemically treated to obtain a part formed by a CMC material with desired chemical composition. For example, the preform can be cured or burned out to produce a high carbon residue in the preform, and then melt-infiltrated with silicon, or cured or pyrolyzed to produce a silicon carbide matrix in the preform, and then chemical vapor infiltration is performed with silicon carbide. Additional steps can be taken before or after chemical vapor infiltration to improve the densification of the preform, by injecting liquid resin or polymer into the preform, and then performing a heat treatment step to fill the gap with silicon carbide. As used herein, the CMC material can be formed using any known or future developed method, including but not limited to melt infiltration, chemical vapor infiltration, polymer impregnation pyrolysis (PIP) or any combination thereof.

[0037] As used herein, the term "metal" refers to materials including metals, such as, but not limited to, titanium, iron, aluminum, stainless steel, and nickel alloys. A metallic material or alloy may be a combination of at least two or more elements or materials, at least one of which is a metal.

[0038] Conventional two-dimensional (2D) layup designs commonly used to form composite gas turbine engine components are difficult to manufacture and may have limited interlaminar strength. Specifically, composite components for gas turbine engines are often constructed using hand layups or by combining multiple woven or prefabricated preforms into a single molded part. Hand layups or assembly of preforms increases the labor and cost required to build the component. Assembly of preforms also presents assembly and positioning challenges. Furthermore, composite components formed from 2D plies or multiple preforms will more likely have limited interlaminar load capacity.

[0039] The casing structure is used to house various parts of a turbine engine, such as a fan casing for accommodating a fan, a low-pressure (LP) turbine casing for accommodating an LP turbine, and an LP compressor casing for accommodating an LP compressor. Each casing structure may be provided with a flange for coupling to another casing structure. The flange may be integrally formed with the casing structure. Flanges on the casing structures typically have angular corners (e.g., square corners). For example, a first square corner of a first flange of a first casing structure is coupled to a second square corner of a second flange of a second casing structure. The first square corner and the second square corner are aligned such that the first surface of the first square corner and the second surface of the second square corner are substantially aligned to form a continuous airflow surface. The first square corner and the second square corner also improve the compressive strength of the joint between the first and second flanges. Traditionally, integral flange corners (also known as heels) are constructed and formed by manually adding additional buildup and machining layers. However, these flange corners with additional buildup have mechanical weaknesses and may be susceptible to cracking and failure, resulting in a loss of structural integrity of the flange.

[0040] The present preform and method for making a shell structure integrate additional and / or relatively large fiber bundles in the flange area of the shell structure during the process of preforming the flange corners in the shell structure. The present preform and method for making a shell structure can be used for integral flanges composed of various preforms (e.g., three-dimensional (3D) woven fabrics, two-dimensional (2D) woven fabrics, or braids). In addition, the present preform and method for making a shell structure can be used for various shell structures, such as a fan housing and / or a front frame shell.

[0041] Instead of manually laying down additional buildup layers and / or machining plies, additional and / or larger fiber bundles are integrally woven in the flange area to construct the flange corner (also known as the heel), which provides strength to the flange corner and the entire flange. Furthermore, the top surface of the fiber preform in the flange corner area can be provided with a reduced number of fiber bundles and / or fiber bundles having a smaller diameter (i.e., a bundle of fibers) to form a smaller and / or smoother inner radius. Furthermore, at the outer radius of the flange corner, additional and / or larger fiber bundles can be automatically integrated using a three-dimensional (3D) weaving process or a two-dimensional (2D) weaving or braiding process.

[0042] The present flange structure and method are applicable to typical integral ninety-degree upturned flanges, or any structural member constructed from straight prefabricated members bent to a desired angle (e.g., angles from thirty to one hundred and fifty degrees). The present flange structure and method improve the square corner manufacturing process. The square corner manufacturing process also provides a stronger flange structure and better load-bearing capacity for bolted joints compared to flange structures without the benefit of the present disclosure.

[0043] Referring now to the accompanying drawings, Figure 1 is a schematic cross-sectional view of a turbine engine 10 according to an embodiment of the present disclosure. Figure 1 As shown, the turbine engine 10 defines an axial direction A (extending parallel to a longitudinal centerline axis 12 for reference) and a radial direction R orthogonal to the axial direction A. Generally, the turbine engine 10 includes a fan section 14 and a turbocharger 16 disposed downstream of the fan section 14 .

[0044] The illustrated turbocharged engine 16 generally includes an outer casing 18 that is substantially tubular and defines an annular core inlet 20. Figure 1 As schematically shown in FIG, outer casing 18 encloses a compressor section 21 in a series flow relationship. Compressor section 21 includes a supercharger or low-pressure (LP) compressor 22, followed downstream by a high-pressure (HP) compressor 24; a combustion section 26; a turbine section 27; turbine section 27 includes a high-pressure (HP) turbine 28, followed downstream by a low-pressure (LP) turbine 30; and an exhaust nozzle section 32. A high-pressure (HP) shaft or spool 34 drivingly connects HP turbine 28 to HP compressor 24 so that the HP turbine 28 and the HP compressor rotate in unison. A low-pressure (LP) shaft 36 drivingly connects LP turbine 30 to LP compressor 22 so that the LP turbine 30 and the LP compressor 22 rotate in unison. The compressor section 21, combustion section 26, turbine section 27, and exhaust nozzle section 32 together define a core air flow path.

[0045] for Figure 1 In the illustrated embodiment, fan section 14 includes a fan 38 (eg, a variable pitch fan) having a plurality of fan blades 40 coupled to a disk 42 in a spaced-apart manner. Figure 1 As shown, fan blades 40 extend outwardly from disk 42 generally in a radial direction R. Each fan blade 40 is rotatable relative to disk 42 about a pitch axis P by virtue of fan blades 40 being operably coupled to an actuating member 44 that is configured to collectively and uniformly change the pitch of fan blades 40. Fan blades 40, disk 42, and actuator 44 are rotatable together about longitudinal centerline axis 12 via fan shaft 45, which is powered by LP shaft 36 across a power gearbox 46. Power gearbox 46 includes a plurality of gears for adjusting the rotational speed of fan shaft 45, and thereby adjusting the rotational speed of fan 38 relative to LP shaft 36, to achieve a more efficient fan speed.

[0046] Still refer to Figure 1In the exemplary embodiment of the present invention, the disk 42 is covered by a rotatable fan hub 48 having an aerodynamic profile to facilitate airflow through the plurality of fan blades 40. In addition, the fan section 14 includes an annular fan casing or nacelle 50 that circumferentially surrounds the fan 38 and / or at least a portion of the turbocharger engine 16. The nacelle 50 is supported relative to the turbocharger engine 16 by a plurality of circumferentially spaced outlet guide vanes 52. In addition, a downstream section 54 of the nacelle 50 extends over an outer portion of the turbocharger engine 16 to define a bypass airflow passage 56 therebetween.

[0047] During operation of turbine engine 10, a volume of air 58 enters turbine engine 10 through nacelle 50 and / or inlet 60 of fan section 14. As volume of air 58 passes through fan blades 40, a first portion 62 of the air is directed or channeled into bypass airflow passage 56, while a second portion 64 of the air is directed or channeled into an upstream section of the core air flow path, or more specifically, into annular inlet 20 of LP compressor 22. The ratio between first portion 62 of air and second portion 64 of air is generally referred to as a bypass ratio. The pressure of second portion 64 of air then increases as it is directed through HP compressor 24 and into combustion section 26, where the high-pressure air is mixed with fuel and combusted to produce combustion gases 66.

[0048] The combustion gases 66 are directed into and expanded by the HP turbine 28, where a portion of the thermal and / or kinetic energy from the combustion gases 66 is extracted via successive stages of HP turbine stator blades 68 coupled to the outer casing 18 and HP turbine rotor blades 70 coupled to the HP shaft or spool 34, thereby rotating the HP shaft or spool 34 and thereby supporting the operation of the HP compressor 24. The combustion gases 66 are then directed into and expanded by the LP turbine 30. Here, a second portion of the thermal and kinetic energy is extracted from the combustion gases 66 via successive stages of LP turbine stator blades 72 coupled to the outer casing 18 and LP turbine rotor blades 74 coupled to the LP shaft 36, thereby rotating the LP shaft 36. This, in turn, supports the operation of the LP compressor 22 and the rotation of the fan 38 via the power gearbox 46.

[0049] The combustion gases 66 are then directed through the jet exhaust nozzle section 32 of the turbocharger engine 16 to provide propulsive thrust. Simultaneously, the pressure of the first portion of air 62 is significantly increased as it is directed through the bypass airflow passage 56 before being discharged from the fan nozzle exhaust section 76 of the turbine engine 10, also providing propulsive thrust. The HP turbine 28, the LP turbine 30, and the jet exhaust nozzle section 32 at least partially define a hot gas path 78 for directing the combustion gases 66 through the turbocharger engine 16.

[0050] Figure 1 The turbine engine 10 shown in FIG. 1 is for example only. In other exemplary embodiments, the turbine engine 10 can have any other suitable configuration. For example, in other exemplary embodiments, the fan 38 can be configured in any other suitable manner (e.g., as a fixed pitch fan) and can also be supported using any other suitable fan frame configuration. In addition, in other exemplary embodiments, any other suitable number or configuration of compressors, turbines, shafts, or combinations thereof can be provided. In other exemplary embodiments, aspects of the present disclosure can be incorporated into any other suitable gas turbine engine, such as a turbofan engine, a propfan engine, a turbojet engine, and / or a turboshaft engine.

[0051] The casing structures are used to house various parts of the turbine engine, such as a fan casing 110 for housing fan blades 40 , an LP turbine casing 112 for housing the LP turbine 30 , an LP compressor casing 114 for housing the LP compressor 22 , etc. Each casing structure may be provided with a flange for coupling to another flange of another casing structure.

[0052] Figure 2 is a cross-sectional view of two flanges coupled to each other according to an embodiment of the present disclosure. Figure 2 As shown, the first flange 202 is integrated with the first housing structure 201 , and the second flange 204 is integrated with the second housing structure 203 . Figure 2 Only a portion of the first shell structure 201 and a portion of the second shell structure 203 are shown. The first flange 202 of the first shell structure 201 generally has a first angular corner 202A (e.g., a first square corner). The second flange 204 of the second shell structure 203 generally has a second angular corner 204A (e.g., a first square corner). The first flange 202 and the second flange 204 are coupled to each other at the first angular corner 202A and the second angular corner 204A using fasteners 206 (e.g., bolts and nuts). The fasteners 206 are used to bring the first flange 202 and the second flange 204 into close contact with each other, such that the first contact surface 202B of the first angular corner 202A of the first flange 202 contacts the second contact surface 204B of the second angular corner 204A of the second flange 204. Figure 2As shown, a load spreader 208 may be disposed between the fastener 206 and the first angled comer 202A. The load spreader 208 serves to distribute the load applied by the fastener 206 to the first angled comer 202A. For example, if the fastener 206 is a bolt and nut combination, the load spreader 208 (e.g., a washer-like element) may be used to distribute the load applied by the head of the bolt. Alternatively, or in addition, another load spreader (not shown) may be disposed between the fastener 206 and the second angled comer 204A. The load spreader 208 may be made, for example, of metal.

[0053] The first angled corner 202A and the second angled corner 204A are aligned such that the first inner radius surface 202C of the first angled corner 202A and the second inner radius surface 204C of the second angled corner 204A are substantially aligned to form a continuous airflow surface 210. The term "substantially aligned" is used herein to mean that the first inner radius surface 202C and the second inner radius surface 204C form a plane at a certain level, and the angle between the first inner radius surface 202C and the second inner radius surface 204C is approximately zero degrees, plus or minus two degrees. The contact between the first angled corner 202A and the second angled corner 204A can also increase the compressive strength joint between the first flange 202 and the second flange 204.

[0054] like Figure 2 As shown, the first angular comer 202A also has a first outer radius surface 202D that is angled (e.g., approximately 90 degrees). Similarly, the second angular comer 204A has a second outer radius surface 204D that is angled (e.g., approximately 90 degrees). The fastener 206 and / or the load spreader 208 contact the first outer radius surface 202D. In an embodiment, the fastener 206 may also contact the second outer radius surface 204D. The terms "inner radius surface" and "outer radius surface" refer to the surface radially closest to the longitudinal centerline axis 12 and the surface radially farthest from the longitudinal centerline axis, respectively.

[0055] Traditionally, the angular corners of flanges (also known as the heels) have been constructed and formed by manually adding additional build-up layers and machining plies. However, these angular corners of flanges with additional build-up layers present mechanical weaknesses and are therefore susceptible to cracking (e.g., at the angular corners) and failure, which can cause the flange to lose its structural integrity.

[0056] The present flange structure and method for manufacturing the flange structure integrate additional fiber bundles and / or fiber bundles with larger diameters into the flange area during the process of preforming the flange corners. The present flange structure and method can be used for integral flanges constructed from various preforms (e.g., three-dimensional (3D) woven fabrics, two-dimensional (2D) woven fabrics, or braids). Furthermore, the present flange structure and method can be used for various housing structures, such as fan housings and front frame shells.

[0057] Figure 3A 2 is a schematic representation of a portion of a first shell structure 201 before forming a first flange 202 according to an embodiment of the present disclosure. In an embodiment, the first shell structure 201 is formed of various preforms (e.g., a three-dimensional (3D) woven (also known as a Z-woven) structure, a two-dimensional (2D) woven structure, or a braided structure). However, in order to consider the first angular corner 202A of the first flange 202 (e.g., Figure 2 ), the reinforcing fiber bundles (e.g., carbon fibers) within the three-dimensional (3D) woven fabric or two-dimensional (2D) woven fabric of the preform are selected and arranged so that additional or larger reinforcing fiber bundles are provided at the first angular corner 202A during the 3D weaving process. For example, Figure 3A As shown, the first angular corner 202A of the first flange 202 (as shown in FIG. Figure 2 ) has a protrusion 214 in the area 212 of the first flange 202. The protrusion 214 corresponds to the area where the three-dimensional (3D) woven structure is configured for constructing the first angled corner 202A before forming the first angled corner 202A.

[0058] Figure 3B The first angled corner 202A (eg, Figure 2 Schematic cross section of a region 301 of a 3D woven preform 300 used at a first angled corner 202A of a first flange 202 of a first shell structure 201. The region 301 of the 3D woven preform 300 used at a first angled corner 202A of a first flange 202 of a first shell structure 201 corresponds to Figure 2 The region 212 showing the protrusion 214 is shown. The 3D woven preform 300 is selected to increase the stiffness or strength at the first angular corner 202A of the first flange 202 of the first shell structure 201 .

[0059] like Figure 3B As shown, region 301 of 3D woven preform 300 includes a first plurality of reinforcing fiber bundles 302 (e.g., carbon fibers), a second plurality of reinforcing fiber bundles 304 (e.g., carbon fibers), and a third plurality of reinforcing fiber bundles 306 (e.g., carbon fibers). For clarity, Figure 3BNot shown are the fourth plurality of reinforcing fiber bundles for connecting the first plurality of reinforcing fiber bundles 302 (e.g., carbon fibers), the second plurality of reinforcing fiber bundles 304 (e.g., carbon fibers), and the third plurality of reinforcing fiber bundles 306 (e.g., carbon fibers). The fourth plurality of reinforcing fiber bundles may be referred to as interlocking fiber bundles or Z-woven fabrics. For example, the first plurality of reinforcing fiber bundles 302 correspond to weft fibers, while the second plurality of reinforcing fiber bundles 304 and the third plurality of reinforcing fiber bundles 306 correspond to warp fibers. In an embodiment, as Figure 3B As shown, the second plurality of reinforcing fiber bundles 304 and the third plurality of reinforcing fiber bundles 306 have different diameters. For example, the diameter of the reinforcing fiber bundles can be changed by changing the number of fibers used in the reinforcing fiber bundles. Figure 3B As shown, the first plurality of reinforcing fiber bundles 302 (weft fibers) extend parallel to the drawing plane, and the second plurality of reinforcing fiber bundles 304 and the third plurality of reinforcing fiber bundles 306 (warp fibers) extend substantially perpendicular to the drawing plane. Therefore, the second plurality of reinforcing fiber bundles 304 (warp fibers) and the third plurality of reinforcing fiber bundles 306 (warp fibers) are substantially perpendicular to the first plurality of reinforcing fiber bundles 302 (weft fibers). The term "substantially perpendicular" is used herein to represent an angle equal to 90 degrees ± 10 degrees. The second plurality of reinforcing fiber bundles 304 and the third plurality of reinforcing fiber bundles 306 are substantially parallel to each other, and the diameter of the second plurality of reinforcing fiber bundles 304 is less than the diameter of the third plurality of reinforcing fiber bundles 306.

[0060] like Figure 3B As shown, at least one of the first plurality of reinforcing fiber bundles 302 is located adjacent the first outer radius surface 202D of the first flange 202. Figure 3C As shown, the second plurality of reinforcement fiber bundles 304 and the third plurality of reinforcement fiber bundles 306 are located adjacent the first inner radius surface 202C of the first flange 202. Figure 3B As shown, the third plurality of reinforcing fiber bundles 306 form a triangular shape 308 with a vertex that is located near the first inner radius surface 202C. Therefore, in an embodiment, the number of the third plurality of reinforcing fiber bundles 306 increases as the distance D from the first inner radius surface 202C increases. In an embodiment, the diameter of each of the third plurality of reinforcing fiber bundles 306 is greater than the diameter of each of the second plurality of reinforcing fiber bundles 304 and the diameter of each of the first plurality of reinforcing fiber bundles 302. By providing an increased number of the third plurality of reinforcing fiber bundles 306 and increasing the distance from the first inner radius surface 202C, it is possible to construct the first angular corner 202A instead of manually laying additional buildup materials and / or processing plies. In addition, the increase in the number of the third plurality of reinforcing fiber bundles 306 from the first inner radius surface 202C increases the rigidity of the first angular corner 202A.

[0061] In an embodiment, instead of or in addition to providing a third plurality of reinforcement fiber bundles 306 having a diameter greater than the diameter of the second plurality of reinforcement fiber bundles 304 and the diameter of the first plurality of reinforcement fiber bundles 302, a higher stiffness modulus can be provided for the third plurality of reinforcement fiber bundles 306. In another embodiment, instead of or in addition to providing a third plurality of reinforcement fiber bundles 306 having a diameter greater than the diameter of the second plurality of reinforcement fiber bundles 304 and the diameter of the first plurality of reinforcement fiber bundles 302, the density (or number) of the third plurality of reinforcement fiber bundles 306 can be increased such that the density of the third plurality of reinforcement fiber bundles 306 can be greater than the density of the second plurality of reinforcement fiber bundles 304 or the density of the first plurality of reinforcement fiber bundles 302 to increase the stiffness and rigidity near the first angular corner 202A.

[0062] When bending and forming the first angular corner 202A, the triangular shape 308 (or V-shape) having the vertex located near the first inner radius surface 202C is rotated so that the vertex of the triangular shape 308 is located at the angle AN of the first angular corner 202A (as shown in FIG. Figure 3C shown).

[0063] In an embodiment, the diameter of each of the second plurality of reinforcement fiber bundles 304 located near the first outer radius surface 202D may be smaller than the diameter of each of the third plurality of reinforcement fiber bundles 306. This feature can form a smaller radius of curvature RA (e.g., Figure 3C As shown in FIG. 2 , when bending and forming the first angular corner 202A, the second plurality of reinforcing fiber bundles 304 having a smaller diameter provide more space or volume for filling or compacting more fibers. In another embodiment, as an alternative or in addition to providing a diameter of the second plurality of reinforcing fiber bundles 304 located near the first outer radial surface 202D that is smaller than the diameter of the third plurality of reinforcing fiber bundles 306, the density (or number) of the second plurality of reinforcing fiber bundles 304 located near the first outer radial surface 202D can also be reduced. Reducing the density of the second plurality of reinforcing fiber bundles 304 located near the first outer radial surface 202D can also provide more space or volume for filling or compacting more fibers when bending and forming the first angular corner 202A.

[0064] Figure 3C FIG. 2 is a schematic representation of a portion of a first shell structure 201 after forming a first flange 202 according to an embodiment of the present disclosure. In an embodiment, considering that a first angular corner 202A of the first flange 202 (e.g., Figure 2), the reinforcing fiber bundles (e.g., carbon fibers) within the three-dimensional (3D) woven fabric or two-dimensional (2D) woven fabric of the preform are selected and arranged so that additional fiber bundles and / or fiber bundles with larger diameters are provided at the first angular corner 202A during the 3D weaving process. The first shell structure 201 is bent to form the first angular corner 202A. As described above with respect to Figure 3B As described above, the first plurality of reinforcing fiber bundles 302, the second plurality of reinforcing fiber bundles 304, and the third plurality of reinforcing fiber bundles 306 are configured to provide or construct the first angular corner 202A by integrally weaving additional fibers and / or fibers having a larger diameter for providing additional strength. When forming the first angular corner 202A, the first outer radius surface 202D is bent to define a curved surface having a radius RA, as shown in FIG. Figure 3C shown.

[0065] Integrally weaving additional fiber bundles and / or fiber bundles with larger diameters in the flange area to construct the flange corner (also referred to as the heel) instead of manually laying up additional build-up layers and / or machining plies provides strength to the flange corner and the entire flange. In addition, the top surface of the fiber preform in the flange corner area can be provided with a reduced number of fiber bundles and / or fiber bundles with smaller diameters to form a smaller and / or smoother inner radius RA (e.g., Figure 3C Furthermore, at the outer radius of the flange corners, additional fiber bundles and / or fiber bundles having larger diameters can be automatically integrated using a three-dimensional (3D) weaving process, a two-dimensional (2D) weaving process, or a braiding process.

[0066] The present flange structure and method are applicable to typical integral ninety-degree upturned flanges, or any structural member constructed from straight prefabricated members bent to a desired angle (e.g., between thirty and one hundred and fifty degrees). The present flange structure and method improve the manufacturing process for angular (e.g., square) corners and provide a stronger flange structure with better load-bearing capacity for use with fasteners such as bolted joints.

[0067] Although carbon fibers are provided above as examples of fibers for forming reinforcing fiber bundles, other types of fibers may be used, including but not limited to glass fibers, carbon fibers, steel fibers, or para-aramid fibers, such as those available from DuPont de Nemours and Company in Wilmington, Delaware. Furthermore, although the above paragraphs describe the use of a three-dimensional woven carbon fiber composite structure in the first flange 202 , a two-dimensional woven fiber composite structure may also be used.

[0068] In an embodiment, after forming the first angular corner 202A of the first flange 202, the 3D woven preform 300 is placed in a mold and then injected with a liquid resin or polymer matrix to fill the gaps not occupied by the first plurality of reinforcing fiber bundles 302, the second plurality of reinforcing fiber bundles 304, and the third plurality of reinforcing fiber bundles 306. The liquid resin or polymer matrix may also include a filler material such as silicon carbide. The 3D woven preform 300 and the resin in the mold may then be heat treated to cure the resin or polymer matrix to obtain the desired solidified shape of the first flange 202. The mold is then removed to form the first flange 202 having the first angular corner 202A.

[0069] Thus, the third plurality of reinforcing fiber bundles 306 are integrated within the first plurality of reinforcing fiber bundles 302 and the second plurality of reinforcing fiber bundles 304. The third plurality of reinforcing fiber bundles 306 are disposed at selected locations within the 3D woven preform 300 (e.g., in a triangular configuration), as described in the above paragraphs. The third plurality of reinforcing fiber bundles 306 are introduced as additional material to the first plurality of reinforcing fiber bundles 302 and the second plurality of reinforcing fiber bundles 304 to provide reinforcement at the first angular corner 202A. When the first shell structure 201 is bent to form the first angular corner 202A, due to the inherent curvature of the reinforcing fiber bundles, the vertex of the angle AN of the first angular corner 202A (e.g., Figure 3C 2A ). However, after adding resin to the reinforcing fiber bundle within the mold, curing the resin, and then removing the mold, the apex of angle AN becomes straight (e.g., a smaller curvature apex). The use of the mold and resin allows the smaller curvature apex of first angular corner 202A to be formed at angle AN.

[0070] In another embodiment, a mold may not be used, in which case the apex may still be curved after providing the resin and curing the resin within the 3D woven preform 300. However, some material at the corner AN can be mechanically removed by removing a sacrificial material layer, which may include hardened resin and a portion of the first plurality of reinforcement fiber bundles 302, a portion of the second plurality of reinforcement fiber bundles 304, and / or a portion of the third plurality of reinforcement fiber bundles 306. By removing the sacrificial material layer, a straight apex at the first angled corner 202A of the first flange 202 can be obtained. However, some of the third plurality of reinforcement fiber bundles 306 still exist within the 3D woven preform 300. Therefore, the first angled corner 202A of the first flange 202 may still have the desired strength qualities.

[0071] In the above paragraphs, the first shell structure 201 and the first flange 202 are described in detail. Similar descriptions can be applied to the second shell structure 203 and the second flange 204 ( Figure 2 As shown in ). Figure 2 As shown, the second housing structure 203 and the second flange 204 are similar in many respects to the first housing structure 201 and the first flange 202 .

[0072] Figure 4A and Figure 4B is a schematic diagram illustrating a three-dimensional fiber weave pattern that may be used to form woven fabric 400. Figure 4B It is along Figure 4A In the embodiments discussed herein, the composite component may be formed from a plurality of reinforcing fibers, and more specifically, a plurality of reinforcing fiber bundles 404. As described above, the plurality of reinforcing fiber bundles 404 may be woven together to form a 3D woven structure, such as Figure 4A The woven fabric 400 shown in FIG, and thus the woven fabric 400 can be woven to form the first shell structure 201, as shown in FIG. Figure 3A and Figure 3C . The plurality of reinforcing fiber bundles 404 of the woven fabric 400 include a plurality of first fiber bundles, which are a plurality of warp fiber bundles 410 in the present embodiment. When forming the first shell structure 201, the warp fiber bundles 410 of the woven fabric 400 include the second plurality of reinforcing fiber bundles 304 and the third plurality of reinforcing fiber bundles 306 discussed above. The plurality of reinforcing fiber bundles 404 also include a plurality of second fiber bundles, which are a plurality of weft fiber bundles 420 in the present embodiment. When forming the first shell structure 201, the weft fiber bundles 420 of the woven fabric 400 include the first plurality of reinforcing fiber bundles 302 discussed above. The weft fiber bundles 420 are transverse to the warp fiber bundles 410 orientation, and in the illustrated embodiment, the warp fiber bundles 410 and the weft fiber bundles 420 are approximately orthogonal to each other orientation. Therefore, the woven fabric 400 includes a warp direction Wp (also referred to as the first direction) and a weft direction Wf (also referred to as the second direction). The warp fiber bundles 410 extend in the warp direction Wp, and the weft fiber bundles 420 extend in the weft direction Wf.

[0073] In the depicted embodiment, the woven fabric 400 is a three-dimensional woven fabric and further includes a thickness direction t. The thickness direction may also be referred to as the z-direction. Warp fiber bundles 410 are arranged in both the weft direction Wf and the thickness direction t. The warp fiber bundles 410 may be parallel to each other in both the weft direction Wf and the thickness direction t, and the woven fabric 400 may include a plurality of warp fiber layers 412 in the thickness direction t and a plurality of warp fiber columns 414 in the weft direction Wf. Figure 4A and Figure 4B Three warp fiber layers 412 are depicted in FIG, but the woven fabric 400 may include any other number of warp fiber layers 412 , including more than three warp fiber layers 412 .

[0074] During the weaving process, the warp fiber bundles 410 can be held taut in the warp direction Wp, and one of the weft fiber bundles 420 is passed through or pulled through it. A shuttle (not shown) can be used to pull one of the weft fiber bundles 420 through the warp fiber bundles 410. The shuttle can pass through the warp fiber bundles 410 in a first direction and then reverse to pass through the warp fiber bundles 410 at different heights in the thickness direction, thereby forming multiple weft fiber layers 422 in the thickness direction t. One of the weft fiber bundles 420 can continuously pass through at least a portion of the thickness of the woven fabric 400, and one of the weft fiber bundles 420 can include a portion extending in the thickness direction t, which in some embodiments can be referred to as a turning portion. Therefore, this portion of the weft fiber bundle can be referred to herein as a turning portion 424. The warp fiber bundles 410 can move relative to each other to leave space for one of the weft fiber bundles 420 to pass through. The warp fiber bundles 410 can be moved relative to each other in different ways to produce different patterns. Thus, weaving the woven fabric 400 includes positioning the warp fiber bundles 410 (e.g., such that the warp fiber bundles 410 remain taut and stationary), then laying the weft fiber bundles 420 (e.g., such that the weft fiber bundles 420 are pulled through and inserted over and under corresponding warp fibers 410), and repeating this process until the woven fabric 400 is formed. The weft fiber bundles 420 can be parallel to each other in both the warp direction Wp and the thickness direction t, and the woven fabric 400 can include a plurality of weft fiber layers 422 in the thickness direction t and a plurality of weft fiber columns 426 in the warp direction Wp.

[0075] The woven fabric 400 also includes a plurality of interlocking fiber bundles 430 (also referred to as Z-woven fiber bundles). As described above, in forming the first shell structure 201 (e.g. Figure 3A and Figure 3C ), the interlocking fiber bundles 430 of the woven fabric 400 include a fourth plurality of reinforcing fiber bundles. The interlocking fiber bundles 430 are additional warp fiber bundles that are guided through the thickness of the woven fabric 400 during weaving to stitch the plurality of reinforcing fiber bundles 404 together. The interlocking fiber bundles 430 are woven to extend between two or more weft fiber layers 422. The interlocking fiber bundles 430 can use different fiber patterns. The first interlocking fiber pattern (e.g., Figure 4A and Figure 4B4 (shown) is an orthogonal interlocking pattern, and the interlocking fiber bundles 430 are referred to herein as orthogonal interlocking fiber bundles 432. In this pattern, the orthogonal interlocking fiber bundles 432 extend substantially in a direction orthogonal to the warp direction Wp, which in the illustrated embodiment is the thickness direction t. Like the weft fiber bundles 420, the interlocking fiber bundles 430 (e.g., the orthogonal interlocking fiber bundles 432) may include turning portions 434. In the illustrated embodiment, the turning portions 434 of the orthogonal interlocking fiber bundles 432 are positioned to form an alternating pattern between each warp fiber column 414. In the illustrated embodiment, the orthogonal interlocking fiber bundles 432 extend through the thickness of the woven fabric 400 and may be referred to as through-thickness interlocking fiber bundles, but other thicknesses may be used.

[0076] Figure 4C The second interlocking fiber pattern shown in is an angle interlocking pattern, and more specifically a layer-by-layer angle interlocking pattern. Figure 4C It is from Figure 4B A similar perspective view of a cross-sectional view of a woven fabric. The interlocking fiber bundles 430 are referred to in this embodiment as angled interlocking fiber bundles 436. The angled interlocking fiber bundles 436 do not extend orthogonally through the woven fabric 400, but instead form an oblique angle relative to the warp direction Wp. In the illustrated embodiment, the angled interlocking fiber bundles 436 extend between adjacent weft fiber layers 422 in an alternating or sinusoidal pattern, wherein an oblique angle is formed between adjacent turning portions 434 of the angled interlocking fiber bundles 436. The turning portions 434 of the angled interlocking fiber bundles 436 are located on every other weft fiber column 426, but in other embodiments, two or more weft fiber columns 426 may be located between adjacent turning portions 434 of the angled interlocking fiber bundles 436. In other embodiments, the angled interlocking fiber bundles 436 may extend between more than two adjacent weft fiber layers 422. For example, as Figure 4D As shown, the interlocking fiber bundles 430 are through-thickness interlocking fiber bundles, referred to herein as through-thickness angled interlocking fiber bundles 438 . Figure 4D It is from Figure 4B A similar perspective view of a cross-sectional view of a woven fabric. Figure 4C and Figure 4D The warp fiber bundle 410 is omitted.

[0077] In weaving Figure 4A When woven fabric 400 as shown in FIG, for example, some of the warp fiber bundles 410 may be replaced with larger diameter or denser warp fiber bundles 410 (i.e., second plurality of reinforcement fiber bundles 304 and third plurality of reinforcement fiber bundles 306) to form triangular shape 308 (V-shape).

[0078] Figure 5The manufacturing method according to the embodiment of the present disclosure can be used to make Figure 2 Flowchart of a general process for forming a composite component of a shell structure is shown in FIG. The method includes weaving a woven fabric 400 (3D woven fabric) in step S10, for example, on a loom. In step S20, the method includes forming an initial preform using one or more pieces of woven fabric 400. This step may include, for example, laying down a plurality of woven fabrics 400 or otherwise positioning a plurality of woven fabrics 400 relative to each other to form the initial preform.

[0079] In the case of a 2D woven fabric ply, the 2D woven fabrics are woven together in step S10, and then a plurality of 2D woven fabric plies are laid and connected together in step S20 to form a stack of 2D woven fabric plies. When using 2D woven fabric plies, at step S20, the method includes forming an initial preform using the stack of 2D woven fabric plies. Similar to the 3D woven fabric 400, the 2D woven fabric ply can also replace some of the plurality of reinforcing fibers in the 2D woven fabric ply with reinforcing fibers of larger diameter or denser density to form a triangular shape (V-shape).

[0080] However, the production of preforms is not limited to woven fabrics, but may also be used with reinforcement fiber bundles that are laid down using other processes to form a plurality of plies to form the initial preform in step S20. In this case, step S10 may be omitted and a plurality of reinforcement fiber bundles may be laid down to form the first plurality of reinforcement fiber bundles 302 ( Figure 3B ), the second plurality of reinforcing fiber bundles 304 ( Figure 3B ) and a third plurality of reinforcing fiber bundles 306 ( Figure 3B ). The multiple plies can be laid by hand (i.e., hand-laid) or using an automated process including an automated laying system. The automated laying system and the corresponding automated process can be, for example, an automated tape laying (ATL) system, an automated fiber placement (AFP) system, a thermoplastic fiber / tape placement (TTP) system, a pick and place system, etc.

[0081] In step S30, the initial preform is shaped to form a shaped preform. Shaping the initial preform may include, for example, shaping the initial preform using a mold tool. Suitable forming processes may include vacuum forming or other forming processes to impart shape to the initial preform. The shaped preform may form the final preform, but additional machining and manufacturing processes may optionally be performed on the shaped preform, such as adding inserts, to form the final preform.

[0082] After the preform is completed (i.e., the final preform), the matrix material can be injected into the preform in step S40 to produce an infiltrated (or impregnated) preform. When the composite part is a polymer matrix composite material, in this step, the polymer and / or resin can be pumped, injected, or otherwise provided to the mold or cavity to infiltrate or impregnate the dry fibers. For example, when a resin transfer molding (RTM) process is used, this step can be performed in conjunction with step S30. Other infiltration processes can be used in this step depending on the matrix material. As described above, the preform can be formed using prepreg fiber bundles, and in such embodiments, this step (step S40) can be omitted.

[0083] The method continues with curing the infiltration preform in step S50 to combine the composite material, and more specifically the matrix, together to form a composite component. The curing process depends on the material and may include solidifying or otherwise hardening the matrix material around the fiber bundles within the preform. For example, when the matrix material is a polymer, curing may include solidifying and chemically cross-linking the polymer chains. Curing the infiltration preform may include several processes. For example, the infiltration preform may be thinned and cured by exposing it to high temperature and high pressure in an autoclave. The infiltration preform may also undergo one or more further processes, such as a burnout cycle and a densification process. The curing step S50 may be performed in conjunction with step S40, for example, when the matrix material is injected into the final preform in a molten state and the curing step includes cooling the matrix material.

[0084] During the process of preforming the flange corner, the present flange structure and method of making the flange structure integrates additional and / or reinforcing fiber bundles (third plurality of reinforcing fiber bundles 306) having a diameter greater than the diameter of other reinforcing fiber bundles within the 3D or 2D woven structure into the flange area. The present flange structure and method can be used for integral flanges composed of various preforms (e.g., three-dimensional (3D) woven fabrics, two-dimensional (2D) woven fabrics, or braids), as described in the above paragraphs. In addition, the present flange structure and method can be used for various housing structures, such as fan containment housings, front frame shells, or both.

[0085] Integrally weaving additional and / or larger fiber bundles in the flange area to construct the flange corner (also known as the heel) rather than manually laying down additional buildup and / or machining plies provides strength to the flange corner and the entire flange. Furthermore, the outer radius surface of the fiber preform in the flange corner area can be provided with a reduced number of fiber bundles and / or fiber bundles having smaller diameters to create a smaller and / or smoother inner radius. Furthermore, at the outer radius of the flange corner, additional fiber bundles and / or fiber bundles having larger diameters can be automatically integrated using a three-dimensional (3D) weaving process or a two-dimensional (2D) weaving or braiding process.

[0086] The present flange structure and method are applicable to typical integral ninety-degree upturned flanges, or any structural member constructed from straight prefabricated members bent to a desired angle (e.g., angles from thirty to one hundred and fifty degrees). The present flange structure and method improve the square corner manufacturing process. The square corner manufacturing process also provides a stronger flange structure and better load-bearing capacity for use with fasteners (e.g., bolted joints).

[0087] Further aspects are provided by the subject matter of the following clauses.

[0088] A preform for making a shell structure, the preform comprising: a plurality of reinforcing fiber bundles, the plurality of reinforcing fiber bundles being arranged in a two-dimensional woven structure, a three-dimensional woven structure, or a braided structure, wherein the plurality of reinforcing fiber bundles include integrally woven or braided fiber bundles, the diameter or density of the integrally woven or braided fiber bundles being greater than the corresponding diameter or density of other woven or braided fiber bundles, and wherein the integrally woven or braided fiber bundles are located in an area of the preform that is bent to form an angular corner, thereby providing strength to the shell structure including the angular corner.

[0089] The preform of the preceding clause, wherein the angular corner of the preform is thirty degrees to one hundred and fifty degrees.

[0090] The preform of any of the preceding clauses, wherein each of the plurality of reinforcing fiber bundles comprises a plurality of carbon fibers, a plurality of glass fibers, a plurality of steel fibers, a plurality of para-aramid fibers, or any combination thereof.

[0091] The preform of any of the preceding clauses, wherein the plurality of reinforcing fiber bundles comprises a first plurality of reinforcing fiber bundles, a second plurality of reinforcing fiber bundles, and a third plurality of reinforcing fiber bundles, and wherein the third plurality of reinforcing fiber bundles comprises the integrally woven or braided fiber bundles.

[0092] The preform of any of the preceding clauses, wherein the diameter of the third plurality of reinforcement fiber bundles is greater than the diameter of the first plurality of reinforcement fiber bundles and the diameter of the second plurality of reinforcement fiber bundles.

[0093] The preform of any of the preceding clauses, wherein the density of the third plurality of reinforcement fiber bundles is greater than the density of the first plurality of reinforcement fiber bundles and the density of the second plurality of reinforcement fiber bundles.

[0094] A preform according to any preceding clause, wherein the two-dimensional woven structure or the three-dimensional woven structure defines an outer radius surface and an inner radius surface of the preform, and the integrally woven or braided fiber bundle is located adjacent the inner radius surface.

[0095] The preform of any preceding clause, wherein the third plurality of reinforcement fiber bundles increases in number with increasing distance from the inner radius surface so as to form a triangle having an apex located adjacent the inner radius surface.

[0096] The preform of any of the preceding clauses, wherein the diameter of the second plurality of reinforcement fiber bundles located near the outer radial surface of the preform is smaller than the diameter of the third plurality of reinforcement fiber bundles located near the inner radial surface of the preform, so as to form a smaller radius of curvature when forming the angular corner of the preform.

[0097] A shell structure having an integral flange, comprising a preform according to any one of the preceding clauses, the angular corner forming part of the integral flange; and a polymer matrix material, wherein the plurality of reinforcing fiber bundles of the preform are embedded in the polymer matrix material.

[0098] A three-dimensional woven structure comprising a first plurality of reinforcing fiber bundles, a second plurality of reinforcing fiber bundles, and a third plurality of reinforcing fiber bundles. The diameter of each of the third plurality of reinforcing fiber bundles is greater than the diameter of each of the first plurality of reinforcing fiber bundles and the diameter of each of the second plurality of reinforcing fiber bundles, or the density of the third plurality of reinforcing fiber bundles is greater than the density of the first plurality of reinforcing fiber bundles, the density of the second plurality of reinforcing fiber bundles, or both. The number of the third plurality of reinforcing fiber bundles increases with increasing distance from an inner radius surface of the three-dimensional woven structure so as to form a triangle having a vertex located near the inner radius surface.

[0099] The three-dimensional woven structure of the preceding clause, wherein each of the first plurality of reinforcing fiber bundles, the second plurality of reinforcing fiber bundles, and the third plurality of reinforcing fiber bundles comprises a plurality of carbon fibers, a plurality of glass fibers, a plurality of steel fibers, a plurality of para-aramid fibers, or any combination thereof.

[0100] The three-dimensional woven structure of any of the preceding clauses, wherein the first plurality of reinforcing fiber bundles corresponds to weft fibers, and the second and third pluralities of reinforcing fiber bundles correspond to warp fibers.

[0101] The three-dimensional woven structure of any of the preceding clauses, wherein the third plurality of reinforcement fiber bundles are located adjacent the inner radius surface.

[0102] The three-dimensional woven structure of any of the preceding clauses, wherein the second and third plurality of reinforcing fiber bundles are substantially perpendicular to the first plurality of reinforcing fiber bundles.

[0103] The three-dimensional woven structure of any of the preceding clauses, wherein the second and third plurality of reinforcement fiber bundles are substantially parallel to one another.

[0104] The three-dimensional woven structure of any of the preceding clauses, wherein the third plurality of reinforcing fiber bundles increases in number with increasing distance from the inner radius surface to form a triangle having a vertex located near the inner radius surface.

[0105] The three-dimensional woven structure of any of the preceding clauses, wherein the third plurality of reinforcement fiber bundles are distributed at selected locations within the three-dimensional woven structure so as to define a triangular shape.

[0106] A turbine engine includes a casing structure having an integral flange, the casing structure comprising a preform and a polymer matrix material. The preform includes: a plurality of reinforcing fiber bundles arranged in a two-dimensional woven structure, a three-dimensional woven structure, or a braided structure, wherein the plurality of reinforcing fiber bundles include integrally woven or braided fiber bundles having a diameter or density greater than the corresponding diameter or density of other woven or braided fiber bundles, and wherein the integrally woven or braided fiber bundles are located in an area of the preform where the preform bends to form an angular corner, thereby providing strength to the casing structure including the angular corner, the angular corner forming part of the integral flange, and wherein the plurality of reinforcing fiber bundles of the preform are embedded in the polymer matrix material.

[0107] The turbine engine according to the preceding clause, wherein said angular corner of said preform is between thirty and one hundred fifty degrees.

[0108] The turbine engine of any of the preceding clauses, wherein each of the plurality of reinforcing fiber bundles comprises a plurality of carbon fibers, a plurality of glass fibers, a plurality of steel fibers, a plurality of para-aramid fibers, or any combination thereof.

[0109] The turbine engine according to any of the preceding clauses, wherein the polymer matrix material comprises a thermosetting resin, a thermoplastic resin, a bismaleimide (BMI) material, or a polyimide material, or any combination thereof.

[0110] The turbine engine of any of the preceding clauses, wherein the plurality of reinforcing fiber bundles comprises a first plurality of reinforcing fiber bundles, a second plurality of reinforcing fiber bundles, and a third plurality of reinforcing fiber bundles, and wherein the third plurality of reinforcing fiber bundles comprises the integrally woven or braided fiber bundles.

[0111] The turbine engine of any of the preceding clauses, wherein the diameter of each of the third plurality of reinforcing fiber bundles is greater than the diameter of each of the first plurality of reinforcing fiber bundles and the diameter of the second plurality of reinforcing fiber bundles.

[0112] The turbine engine of any preceding clause, wherein the density of the third plurality of reinforcing fiber bundles is greater than the density of the first plurality of reinforcing fiber bundles and the density of the second plurality of reinforcing fiber bundles.

[0113] A turbine engine according to any of the preceding clauses, wherein the two-dimensional woven structure, the three-dimensional woven structure or the braided structure defines an outer radial surface and an inner radial surface of the preform, and the integrally woven reinforcement fiber bundles are located adjacent the inner radial surface.

[0114] A turbine engine according to any preceding clause, wherein the number of said third plurality of reinforcing fiber bundles increases with increasing distance from said inner radius surface so as to form a triangle having an apex located near said inner radius surface.

[0115] The turbine engine according to any of the preceding clauses, wherein the diameter of the second plurality of reinforcing fiber bundles located near the outer radial surface of the preform is smaller than the diameter of the third plurality of reinforcing fiber bundles located near the inner radial surface of the preform so as to form a smaller radius of curvature when forming the angular corner of the preform.

[0116] The turbine engine according to any of the preceding clauses, wherein the polymer matrix material comprises a thermosetting resin, a thermoplastic resin, a bismaleimide (BMI) material, or a polyimide material, or any combination thereof.

[0117] Turbine engine according to any of the preceding clauses, wherein the casing structure may be part of a casing of a fan of the turbine engine, part of a casing of a low-pressure turbine of the turbine engine or part of a casing of a low-pressure compressor of the turbine engine.

[0118] A method for making a shell structure comprising a plurality of reinforcing fiber bundles arranged in a two-dimensional woven structure or a three-dimensional woven structure. The method comprises: integrally weaving or braiding the reinforcing fiber bundles, wherein the diameter or density of the reinforcing fiber bundles is greater than the corresponding diameter or density of other reinforcing fiber bundles in the two-dimensional woven structure or the three-dimensional woven structure; positioning the integrally woven reinforcing fiber bundles in the two-dimensional woven structure, the three-dimensional woven structure, or the braided structure to provide strength to the angular corners of the shell structure; adding a polymer matrix to the two-dimensional woven structure, the three-dimensional woven structure, or the braided structure so that the plurality of reinforcing fiber bundles are embedded in the polymer matrix; and curing the polymer matrix to obtain the shell structure.

[0119] The method according to the preceding clause, wherein the polymer matrix is added to the two-dimensional woven structure or the three-dimensional woven structure so that the plurality of reinforcing fiber bundles are embedded in the polymer matrix, comprising injecting the polymer matrix into a mold containing the two-dimensional woven structure or the three-dimensional woven structure to fill the voids not occupied by the plurality of reinforcing fiber bundles, curing the polymer matrix containing the plurality of reinforcing fiber bundles, and removing the mold to form the shell structure having the angular corners.

[0120] The method according to any of the preceding clauses, further comprising shaping the initial preform to form a shaped preform having the angular corner, the shaped preform having the integrally woven reinforcement fiber bundles arranged in the two-dimensional woven structure or the three-dimensional woven structure to provide strength to the angular corner.

[0121] The method according to any one of the preceding clauses further includes integrally weaving reinforcing fiber bundles, wherein the diameter or density of the reinforcing fiber bundles is greater than the corresponding diameter or density of other reinforcing fiber bundles in the two-dimensional woven structure or the three-dimensional woven structure; forming a protrusion at the area of the initial preform where the angular corner is to be formed; and bending the initial preform at the protrusion to form the shaped preform having the angular corner.

[0122] Although the above description is directed to preferred embodiments of the present disclosure, other changes and modifications will be apparent to those skilled in the art and may be made without departing from the present disclosure. In addition, even if not explicitly stated above, features described in conjunction with one embodiment of the present disclosure may also be used in conjunction with other embodiments.

Claims

1. A prefabricated part for making a shell structure, characterized in that: The prefabricated component comprises: a plurality of reinforcing fiber bundles, wherein the plurality of reinforcing fiber bundles are arranged in a two-dimensional woven structure, a three-dimensional woven structure, or a braided structure, wherein the plurality of reinforcing fiber bundles include integrally woven or braided fiber bundles, the diameter or density of the integrally woven or braided fiber bundles being greater than the corresponding diameter or density of other woven or braided fiber bundles in the two-dimensional woven structure, the three-dimensional woven structure, or the braided structure, and The integrally woven or braided fiber bundles are located in the area of the preform where it is bent to form an angular corner, thereby providing strength to the shell structure including the angular corner.

2. The preform according to claim 1, characterized in that in, The angle of the angle is from thirty degrees to one hundred and fifty degrees.

3. The preform according to claim 1, characterized in that in, Each of the plurality of reinforcing fiber bundles includes a plurality of carbon fibers, a plurality of glass fibers, a plurality of steel fibers, a plurality of para-aramid fibers, or any combination thereof.

4. The preform according to claim 1, characterized in that in, The plurality of reinforcing fiber bundles includes a first plurality of reinforcing fiber bundles, a second plurality of reinforcing fiber bundles, and a third plurality of reinforcing fiber bundles, and the third plurality of reinforcing fiber bundles includes the integrally woven or braided fiber bundles.

5. The preform according to claim 4, characterized in that in, A diameter of each of the third plurality of reinforcing fiber bundles is larger than a diameter of each of the first plurality of reinforcing fiber bundles and a diameter of each of the second plurality of reinforcing fiber bundles.

6. The preform according to claim 4, characterized in that in, The density of the third plurality of reinforcing fiber bundles is greater than the density of the first plurality of reinforcing fiber bundles and the density of the second plurality of reinforcing fiber bundles.

7. The preform according to claim 4, characterized in that in, The two-dimensional woven structure, the three-dimensional woven structure, or the braided structure defines an outer radius surface and an inner radius surface of the preform, and the integrally woven or braided fiber bundle is located adjacent to the inner radius surface.

8. The preform according to claim 7, characterized in that in, The number of the third plurality of reinforcing fiber bundles increases with increasing distance from the inner radius surface to form a triangle having a vertex located near the inner radius surface.

9. The preform according to claim 7, characterized in that in, The diameter of the second plurality of reinforcing fiber bundles located near the outer radial surface of the preform is smaller than the diameter of the third plurality of reinforcing fiber bundles located near the inner radial surface of the preform so as to form a smaller radius of curvature when forming the angular corner of the preform.

10. A shell structure with an integral flange, characterized in that: include: The preform of claim 1 , wherein the angled corner forms a portion of the integral flange; and polymer matrix material, Wherein, the plurality of reinforcing fiber bundles of the preform are embedded in the polymer matrix material.

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