Prefabricated components for manufacturing casing structures for turbine engines

Abstract

A preform for fabricating a housing structure for a turbine engine. The preform includes multiple reinforcing fiber bundles arranged in a two-dimensional woven, three-dimensional woven, or braided structure. The multiple reinforcing fiber bundles include integrally woven or braided fiber bundles with a diameter or density greater than the corresponding diameter or density of other woven or braided fiber bundles in the two-dimensional, three-dimensional, or braided structure. The integrally woven or braided fiber bundles are located in regions where the preform is bent to form angular corners, thereby providing strength to the housing structure including the angular corners.

Description

[0001] Government licensing rights

[0002] This invention was completed with the support of the U.S. government. The U.S. government may hold certain rights to this invention. Technical Field

[0003] This disclosure generally relates to housing structures in turbine engines, and more specifically to prefabricated components for manufacturing housing structures for turbine engines. Background Technology

[0004] Turbine engines, such as gas turbine engines, typically include a fan and a turbocharger. Housing structures house the various components of the turbine engine, such as a fan housing. Each housing structure may have flanges for attachment to another housing structure. The flanges may be integrally formed with the housing structure. Flanges on housing structures typically have angular corners (e.g., square corners). Attached Figure Description

[0005] Features and advantages will become apparent from the following more detailed description of various exemplary embodiments as shown in the accompanying drawings, wherein similar reference numerals generally denote identical, functionally similar, and / or structurally similar elements.

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

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

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

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

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

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

[0012] Figure 4B According to embodiments of this disclosure Figure 4A The line 4B-4B is cut off. Figure 4AA schematic cross-sectional view of the fiber weave pattern shown.

[0013] Figure 4C This is a schematic cross-sectional view of a fiber weave pattern according to another embodiment of the present disclosure, shown as... Figure 4A The fiber weaving patterns shown are similar, but they have different interlocking fiber patterns.

[0014] Figure 4D This is a schematic cross-sectional view of a fiber weave pattern according to another embodiment of the present disclosure, shown as... Figure 4A The fiber weaving patterns shown are similar, but they have a different interlocking fiber pattern.

[0015] Figure 5 It is a method for manufacturing according to embodiments of the present disclosure that can be used to produce Figure 2 A flowchart illustrating the general process of the composite component of the shell structure shown. Detailed Implementation

[0016] The features, advantages, and embodiments of this disclosure will be apparent or understood by considering the following detailed description, drawings, and claims. Furthermore, the following detailed description is exemplary and intended to provide further explanation, but not to limit the claimed disclosure.

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

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

[0019] Unless the context clearly indicates otherwise, the singular forms “a,” “one,” and “the” include plural references.

[0020] As used herein, the terms "axial" and "axially" refer to a direction and orientation that extends substantially parallel to the centerline axis of the turbine engine. Furthermore, the terms "radial" and "radially" refer to a direction and orientation that extends substantially perpendicular to the centerline axis of the turbine engine. Additionally, as used herein, the terms "circumferential" and "circumferentially" refer to a direction and orientation that extends in an arc around the centerline axis of the turbine engine.

[0021] As used herein, the terms “first,” “second,” and “third,” etc., are used interchangeably to distinguish one component from another and are not intended to indicate the location or importance of the components.

[0022] As used throughout this specification and claims, approximate language is used to modify any quantitative expression that allows for variation without altering its underlying function. Therefore, values ​​modified by one or more terms such as “about,” “approximately,” and “substantially” are not limited to specified exact values. In at least some cases, approximate language may correspond to the precision of the instrument used to measure the value, or the precision of the method or machine used to construct or manufacture a component and / or system. For example, approximate language may refer to a margin of one percent, two percent, four percent, ten percent, fifteen percent, or twenty percent within a single value, a range of values, and / or the endpoints of a defined range of values.

[0023] Scope limitations are combined and interchanged herein and throughout the specification and claims. Unless the context or language otherwise indicates, such scopes are identified and include all subscopes contained herein. For example, all scopes disclosed herein include endpoints, and endpoints may be combined with each other independently.

[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, nonmetals, or metal and nonmetal components or materials. Examples of composite materials can be, but are not limited to, polymer matrix composites (PMCs), ceramic matrix composites (CMCs), and metal matrix composites (MMCs). Composite materials can be formed from a matrix material and reinforcing elements (e.g., fibers (referred to herein as reinforcing fibers)).

[0025] As used herein, "reinforcing fiber" or "reinforcing fiber bundle" may include, for example, glass fiber, carbon fiber, steel fiber, or para-aramid fiber, such as that available from DuPont, Wilmington, Delaware. The reinforcing fibers can be in the form of fiber bundles, which include multiple fibers forming a bundle. A fiber bundle can include hundreds or thousands of fibers, such as 3000 (3k), 12000 (12k), 24000 (24k), etc. The polymer matrix material can include, for example, thermosetting resins, thermoplastic resins, bismaleimide (BMI) materials, and polyimide materials.

[0026] As used in this article, a “preform” is a three-dimensional woven fabric formed by multiple reinforcing fiber bundles, including warp and weft fiber bundles.

[0027] As used herein, a “composite component” refers to a structure or component comprising any suitable composite material. Composite components (e.g., composite airfoils) may comprise multilayer or sheet composite materials. The stiffness, material, and dimensions of these layers or sheets may vary to achieve a desired composite component or composite portion of a component having a predetermined weight, size, stiffness, and strength.

[0028] Composite components can be formed or joined using one or more layers of adhesive. Adhesives may include resins and phenolic resins, and may require curing at high temperatures or other hardening techniques.

[0029] As may be used herein, PMC refers to a class of materials. PMC materials can be prepregs. A prepreg is a reinforcing material (e.g., reinforcing fibers) pre-impregnated with a polymer matrix material (e.g., a thermoplastic resin). Bundles of reinforcing fibers 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 reinforcing material is drawn through a molten bath of resin; and powder prepreg, in which resin is electrostatically deposited onto the fiber reinforcing material, and then, in a non-limiting example, adhered to the fibers in an oven or by means of heated rollers.

[0030] Resins used as matrix materials for PMCs can generally be classified into thermosetting resin polymers or thermoplastic resin polymers. Thermoplastic resin polymers are typically categorized as polymers that repeatedly soften and flow upon heating and harden upon sufficient cooling due to physical rather than chemical changes. Notable examples of thermoplastic resin polymers include nylon, thermoplastic polyesters, polyaryletherketones (PAEs), and polycarbonate resins. Specific examples of high-performance thermoplastic resins considered for aerospace applications include polyetheretherketone (PEEK), polyetherketoneketone (PEKK), polyetherimide (PEI), polyaryletherketone (PAEK), and polyphenylene sulfide (PPS). Conversely, thermosetting resins do not soften significantly upon heating once fully cured into a rigid solid; instead, they undergo thermal decomposition upon sufficient heating. Notable examples of thermosetting resin polymers include epoxy resins, bismaleimide (BMI), and polyimide resins.

[0031] Another non-limiting example is the use of woven fabrics instead of prepregs containing thermoplastic polymers. Woven fabrics can include, but are not limited to, dry carbon fibers woven together with thermoplastic polymer fibers or filaments. Non-prepreg woven structures can be made in a similar manner. Using this method, the fiber volume of the part can be adjusted by specifying the relative concentrations of the woven or braided thermoplastic fibers and reinforcing fibers. Furthermore, different types of reinforcing fibers can be woven or braided together at various concentrations to adjust the properties of the part. For example, glass fibers, carbon fibers, and thermoplastic fibers can all be woven together at 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 resistance, a design characteristic of parts located near the engine inlet, 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 part. Typically, RTM involves applying dry fibers to a mold or cavity. The dry fibers can include prepreg, braided material, woven material, or any combination thereof. Resin can be pumped in 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. The composite part may require post-curing treatment upon removal from the mold. 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 part or guide the resin. Optionally, additional layers or reinforcing layers of a different material from the dry fibers can be included or added before heating or curing.

[0033] As used herein, CMC refers to a class of materials having reinforcing fibers within 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, alumina (Al₂O₃), silicon dioxide (SiO₂), aluminosilicates (e.g., mullite) or mixtures thereof) or mixtures thereof.

[0034] 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, alumina (Al₂O₃), silicon dioxide (SiO₂), aluminosilicates, or mixtures thereof), or mixtures thereof. Optionally, the ceramic matrix may also 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 a combination of its fiber type / matrix type. 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, and SiC / SiC-SiN represents a silicon carbide fiber reinforced silicon carbide / silicon nitride matrix mixture, etc. In other examples, a CMC can consist of a matrix and reinforcing fibers, which include oxide-based materials such as alumina (Al₂O₃), silicon dioxide (SiO₂), aluminosilicates, and mixtures thereof. Aluminosilicates can include crystalline materials such as mullite (3Al₂O₃·2S₇O₂) and glassy aluminosilicates.

[0036] In some non-limiting examples, the reinforcing fibers may be bundled (e.g., forming reinforcing fiber bundles) and / or coated before being incorporated into the matrix. The bundles of reinforcing fibers (i.e., reinforcing fiber bundles) may be impregnated with a slurry composition before or after the formation of the preform. The preform may then be heat-treated followed by a chemical treatment to obtain a component formed from a CMC material having the desired chemical composition. For example, the preform may be cured or burned off to produce a high-carbon residue in the preform, followed by melt infiltration with silicon, or cured or pyrolyzed to produce a silicon carbide matrix in the preform, followed by chemical vapor infiltration with silicon carbide. Additional steps may be taken before or after chemical vapor infiltration to improve the densification of the preform by injecting a liquid resin or polymer into the preform, followed by a heat treatment step to fill the voids with silicon carbide. The CMC material used herein may be formed using any known or hereafter developed methods, 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 that include metals, such as, but not limited to, titanium, iron, aluminum, stainless steel, and nickel alloys. A metallic material or alloy can be a combination of at least two or more elements or materials, at least one of which is a metal.

[0038] Traditional two-dimensional (2D) layup designs, typically 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 parts into a molded part. The assembly of hand layups or prefabricated parts increases the labor and cost required to build the component. The assembly of prefabricated parts also presents assembly and positioning challenges. Furthermore, composite components formed from 2D sheets or multiple prefabricated parts are more likely to have limited interlaminar load-bearing capacity.

[0039] The housing structure is used to house the various components of a turbine engine, such as a fan housing for a fan, a low-pressure (LP) turbine housing for an LP turbine, and an LP compressor housing for an LP compressor. Each housing structure may have flanges to connect to another housing structure. The flanges may be integrally formed with the housing structure. Flanges on housing structures typically have angular corners (e.g., square corners). For example, a first square corner of a first flange of a first housing structure connects to a second square corner of a second flange of a second housing structure. The first and second square corners 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 and second square corners also improve the compressive strength joint between the first and second flanges. Traditionally, integral flange corners (also called heels) are constructed and formed by manually adding additional layers and machining laminations. However, these flange corners with additional layers have mechanical weaknesses and may be prone to cracking and failure, resulting in a loss of structural integrity of the flange.

[0040] During the preforming process of flange corners in a shell structure, current prefabricated components and methods for fabricating the shell structure integrate additional and / or relatively large fiber bundles into the flange region of the shell structure. Current prefabricated components and methods for fabricating shell structures can be used for integral flanges composed of various prefabricated components, such as three-dimensional (3D) fabrics, two-dimensional (2D) fabrics, or braided fabrics. Furthermore, current prefabricated components and methods for fabricating shell structures can be used for various shell structures, such as fan housings and / or front frame shells.

[0041] Instead of manually laying additional layers and / or processing sheets, additional and / or larger fiber bundles are integrally woven into the flange region to construct the flange corner (also known as the heel), providing strength to the flange corner and the entire flange. Furthermore, the top surface of the fiber preform in the flange corner region can be provided with a reduced number of fiber bundles and / or fiber bundles with smaller diameters (i.e., a single bundle of fibers) to form a smaller and / or smoother inner radius. Additionally, at the outer radius of the flange corner, additional and / or larger fiber bundles can be automatically integrated using three-dimensional (3D) weaving or two-dimensional (2D) weaving or braiding processes.

[0042] This flange structure and method are applicable to typical integral 90-degree upturned flanges, or any structural member constructed from a straight prefabricated member bent to the desired angle (e.g., from 30 to 150 degrees). This flange structure and method improves the manufacturing process for square corners. Compared to flange structures without the benefits of this disclosure, the square corner manufacturing process also provides a more robust flange structure and better load-bearing capacity for use with bolted joints.

[0043] Now refer to the attached diagram, Figure 1 This 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. Typically, the turbine engine 10 includes a fan section 14 and a turbocharger engine 16 disposed downstream of the fan section 14.

[0044] The turbocharged engine 16 shown typically includes a housing 18, which is substantially tubular and defines an annular core inlet 20. (As...) Figure 1 As schematically shown, the housing 18 surrounds the compressor section 21 in a series flow relationship. The compressor section 21 includes a supercharger or low-pressure (LP) compressor 22, downstream of which follows a high-pressure (HP) compressor 24; a combustion section 26; a turbine section 27; the turbine section 27 includes a high-pressure (HP) turbine 28, downstream of which follows a low-pressure (LP) turbine 30; and an injection nozzle section 32. A high-pressure (HP) shaft or spindle 34 drivesly connects the HP turbine 28 to the HP compressor 24 so that the HP turbine 28 and the HP compressor rotate in unison. A low-pressure (LP) shaft 36 drivesly connects the LP turbine 30 to the 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 injection nozzle section 32 together define the core airflow path.

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

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

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

[0048] Combustion gas 66 is directed into and expanded by the HP turbine 28, where a portion of the thermal and / or kinetic energy from the combustion gas 66 is extracted via a series of stages of HP turbine stator blades 68 connected to the housing 18 and HP turbine rotor blades 70 connected to the HP shaft or spool 34, thereby rotating the HP shaft or spool 34 and supporting the operation of the HP compressor 24. The combustion gas 66 is 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 gas 66 via a series of stages of LP turbine stator blades 72 connected to the housing 18 and LP turbine rotor blades 74 connected 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] Combustion gas 66 is then directed through the injection exhaust nozzle section 32 of the turbocharged engine 16 to provide propulsive thrust. Simultaneously, the pressure of the first portion of air 62 increases significantly as it is directed through the bypass airflow passage 56 before exiting from the fan nozzle exhaust section 76 of the turbocharged engine 10, also providing propulsive thrust. The HP turbine 28, LP turbine 30, and injection exhaust nozzle section 32 at least partially define a hot gas path 78 for directing combustion gas 66 through the turbocharged engine 16.

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

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

[0052] Figure 2 This is a cross-sectional view of two flanges joined together according to an embodiment of the present disclosure. Figure 2 As shown, the first flange 202 is integrated with the first housing structure 201. The second flange 204 is integrated with the second housing structure 203. Figure 2 Only a portion of the first housing structure 201 and a portion of the second housing structure 203 are shown. The first flange 202 of the first housing structure 201 typically has a first angular corner 202A (e.g., a first square corner). The second flange 204 of the second housing structure 203 typically has a second angular corner 204A (e.g., a first square corner). The first flange 202 and the second flange 204 are connected 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 diffuser 208 can be disposed between fastener 206 and the first corner 202A. The load diffuser 208 is used to distribute the load applied to the first corner 202A by fastener 206. For example, if fastener 206 is a bolt and nut combination, load diffuser 208 (e.g., a washer-like element) can be used to distribute the load applied by the bolt head. Alternatively, or additionally, another load diffuser (not shown) can be disposed between fastener 206 and the second corner 204A. Load diffuser 208 can be made of, for example, 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 indicate 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 also improves the compressive strength joint between the first flange 202 and the second flange 204.

[0054] like Figure 2 As shown, the first angular corner 202A also has a first outer radius surface 202D forming an angle (e.g., about 90 degrees). Similarly, the second angular corner 204A has a second outer radius surface 204D forming an angle (e.g., about 90 degrees). Fastener 206 and / or load diffuser 208 contact the first outer radius surface 202D. In an embodiment, 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 furthest from the longitudinal centerline axis, respectively.

[0055] Traditionally, the corners (also known as the heels) of flanges are constructed and formed by manually adding additional layers and processing laminations. However, these corners of flanges with additional layers have mechanical weaknesses and are therefore prone to cracking (e.g., at the corners) and failure, which can cause the flange to lose its structural integrity.

[0056] During the preforming process of the flange corner, this flange structure and the method for fabricating the flange structure integrate additional fiber bundles and / or fiber bundles with larger diameters into the flange region. This flange structure and method can be used for integral flanges constructed from various prefabricated materials, such as three-dimensional (3D) fabrics, two-dimensional (2D) fabrics, or braided fabrics. Furthermore, this flange structure and method can be used for various housing structures, such as fan housings and front frame shells.

[0057] Figure 3A This is a schematic representation of a portion of a first housing structure 201 prior to the formation of the first flange 202, according to an embodiment of the present disclosure. In the embodiment, the first housing structure 201 is constructed from various prefabricated elements, such as three-dimensional (3D) woven (also known as Z-woven) structures, two-dimensional (2D) woven structures, or braided structures. However, for the sake of consideration, the first angular corner 202A of the first flange 202 (e.g., Figure 2 As shown, the formation involves selecting and configuring reinforcing fiber bundles (e.g., carbon fibers) within a three-dimensional (3D) or two-dimensional (2D) fabric of the preform, such that additional or larger reinforcing fiber bundles are provided at the first angled corner 202A during the 3D weaving process. For example, as... Figure 3A As shown, the first angled corner 202A of the first flange 202 (as shown) Figure 2 As shown, the first flange 202 has a protrusion 214 in region 212. The protrusion 214 corresponds to the region where a three-dimensional (3D) woven structure is configured for constructing the first corner 202A before the first corner 202A is formed.

[0058] Figure 3B According to an embodiment of the present disclosure, the first angled corner 202A of the first flange 202 of the first housing structure 201 (e.g.) Figure 2 A schematic cross-section of region 301 of the 3D woven preform 300 used at (shown). Region 301 of the 3D woven preform 300 used at the first angular corner 202A of the first flange 202 of the first housing structure 201 corresponds to Figure 2 The area 212 showing the protrusion 214 is displayed. Select the 3D woven preform 300 to increase the stiffness or strength at the first angular corner 202A of the first flange 202 of the first housing structure 201.

[0059] like Figure 3B As shown, region 301 of the 3D woven preform 300 includes a first plurality of reinforcing fiber bundles 302 (e.g., carbon fiber), a second plurality of reinforcing fiber bundles 304 (e.g., carbon fiber), and a third plurality of reinforcing fiber bundles 306 (e.g., carbon fiber). For clarity, Figure 3BA fourth plurality of reinforcing fiber bundles, not shown, are used to connect 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-shaped 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 embodiments, such 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 bundle can be changed by varying the number of fibers used in it. Figure 3B As shown, the first plurality of reinforcing fiber bundles 302 (weft fibers) extend parallel to the plane of the figure, while the second plurality of reinforcing fiber bundles 304 and the third plurality of reinforcing fiber bundles 306 (warp fibers) extend substantially perpendicular to the plane of the figure. 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 denote 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 smaller 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 near the first outer radius surface 202D of the first flange 202. Figure 3C As shown, the second plurality of reinforcing fiber bundles 304 and the third plurality of reinforcing fiber bundles 306 are located near the first inner radius surface 202C of the first flange 202. Figure 3B As shown, a third plurality of reinforcing fiber bundles 306 form a triangular shape 308 with a vertex located near the first inner radius surface 202C. Therefore, in this embodiment, the number of the third plurality of reinforcing fiber bundles 306 increases with an increasing distance D from the first inner radius surface 202C. In this embodiment, the diameter of each of the third plurality of reinforcing fiber bundles 306 is larger 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 third plurality of reinforcing fiber bundles 306 and an increased distance from the first inner radius surface 202C, a first angular corner 202A can be constructed instead of manually laying additional laminated material and / or processing sheets. Furthermore, the increased number of 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 one embodiment, as an alternative or supplement to providing a third plurality of reinforcing fiber bundles 306 having a diameter larger than that of the second plurality of reinforcing fiber bundles 304 and the first plurality of reinforcing fiber bundles 302, a higher stiffness modulus can be provided for the third plurality of reinforcing fiber bundles 306. In another embodiment, as an alternative or supplement to providing a third plurality of reinforcing fiber bundles 306 having a diameter larger than that of the second plurality of reinforcing fiber bundles 304 and the first plurality of reinforcing fiber bundles 302, the density (or number) of the third plurality of reinforcing fiber bundles 306 can be increased, such that the density of the third plurality of reinforcing fiber bundles 306 can be greater than the density of the second plurality of reinforcing fiber bundles 304 or the density of the first plurality of reinforcing fiber bundles 302, to increase the stiffness and rigidity near the first angular corner 202A.

[0062] When the first triangular corner 202A is bent and formed, the triangular shape 308 (or V-shaped shape) with its vertex located near the first inner radius surface 202C rotates such that the vertex of the triangular shape 308 is located at the corner AN of the first triangular corner 202A (e.g., Figure 3C (As shown).

[0063] In an embodiment, the diameter of each of the second plurality of reinforcing fiber bundles 304 located near the first outer radius surface 202D can be smaller than the diameter of each of the third plurality of reinforcing fiber bundles 306. This feature enables the formation of a smaller radius of curvature RA at the first outer radius surface 202D when forming the first angular corner 202A (e.g., ...). Figure 3C (As shown). 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 supplement to providing a smaller diameter than the third plurality of reinforcing fiber bundles 306, the diameter of the second plurality of reinforcing fiber bundles 304 located near the first outer radius surface 202D can also be reduced. Reducing the density of the second plurality of reinforcing fiber bundles 304 located near the first outer radius surface 202D when bending and forming the first angular corner 202A can also provide more space or volume for filling or compacting more fibers.

[0064] Figure 3C This is a schematic representation of a portion of a first housing structure 201 after the formation of the first flange 202, according to an embodiment of the present disclosure. In the embodiment, the first angular corner 202A of the first flange 202 (e.g., Figure 2As shown, the formation involves selecting and configuring reinforcing fiber bundles (e.g., carbon fibers) within a three-dimensional (3D) or two-dimensional (2D) fabric of the prefabricated component, such that additional fiber bundles and / or fiber bundles with larger diameters are provided at the first angled corner 202A during the 3D weaving process. The first shell structure 201 is bent to form the first angled corner 202A. As described above regarding... Figure 3B 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 a first angular corner 202A by integrally weaving additional fibers and / or fibers with a larger diameter, for providing additional strength. In forming the first angular corner 202A, a first outer radius surface 202D is bent to define a curved surface with a radius RA, such as... Figure 3C As shown.

[0065] Instead of manually laying additional layers and / or processing sheets, additional fiber bundles and / or fiber bundles with larger diameters are integrally woven into the flange region to construct the flange corner (also known as the heel), providing strength to the flange corner and the entire flange. Furthermore, the top surface of the fiber preform in the flange corner region 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 (As shown). Furthermore, at the outer radius of the flange corner, additional fiber bundles and / or fiber bundles with larger diameters can be automatically integrated using three-dimensional (3D) weaving, two-dimensional (2D) weaving, or braiding processes.

[0066] This flange structure and method are applicable to typical integral 90-degree upturned flanges, or any structural member constructed from a straight prefabricated member bent to a desired angle (e.g., between 30 and 150 degrees). This flange structure and method improves the manufacturing process of angular (e.g., square) corners and provides a more robust flange structure, as well as better load-bearing capacity for fasteners using fasteners such as bolted joints.

[0067] While carbon fiber has been provided above as an example of a fiber used to form reinforcing fiber bundles, other types of fibers may also be used, including but not limited to glass fiber, carbon fiber, steel fiber, or para-aramid fiber, such as those available from DuPont in Wilmington, Delaware. Or any combination thereof. Furthermore, although the use of a three-dimensional woven carbon fiber composite structure in the first flange 202 is described in the preceding paragraph, 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 a liquid resin or polymer matrix is ​​injected to fill the voids 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 within the mold can then be heat-treated to cure the resin or polymer matrix to obtain the desired solidification shape of the first flange 202. The mold is then removed to form the first flange 202 having the first angular corner 202A.

[0069] Therefore, a 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 preceding paragraphs. The third plurality of reinforcing fiber bundles 306 are introduced as additional material into 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 housing structure 201 is bent to form the first angular corner 202A, due to the inherent curvature of the reinforcing fiber bundles, the apex of angle AN of the first angular corner 202A (e.g., ...) Figure 3C The corner AN is slightly curved or rounded (curved vertex). However, after resin is added to the reinforcing fiber bundle within the mold, the resin is cured, and then the mold is removed, the vertex of corner AN becomes straight (e.g., a smaller curved vertex). The use of the mold and resin allows for the formation of a smaller curved vertex of the first angular corner 202A at corner AN.

[0070] In another embodiment, a mold may not be used. In this case, the vertex may still be curved after the resin is provided and cured within the 3D woven preform 300. However, some material at corner AN can be mechanically removed by removing a sacrificial material layer, which may include hardened resin and portions of a first plurality of reinforcing fiber bundles 302, a second plurality of reinforcing fiber bundles 304, and / or a third plurality of reinforcing fiber bundles 306. By removing the sacrificial material layer, a straight vertex can be obtained at the first angular corner 202A of the first flange 202. However, some of the third plurality of reinforcing fiber bundles 306 remain within the 3D woven preform 300. Therefore, the first angular corner 202A of the first flange 202 may still have the desired strength qualities.

[0071] The first housing structure 201 and the first flange 202 have been described in detail in the preceding paragraphs. A similar description can be applied to the second housing structure 203 and the second flange 204. Figure 2 As shown). Figure 2 As shown, the second housing structure 203 and the second flange 204 are similar to the first housing structure 201 and the first flange 202 in many respects.

[0072] Figure 4A and Figure 4B This is a schematic diagram showing a three-dimensional fiber weaving pattern that can be used to form the woven fabric 400. Figure 4B It is along Figure 4A The image shows a cross-sectional view taken along line 4B-4B. In the embodiments discussed herein, the composite component may be formed from multiple reinforcing fibers, and more specifically, from multiple bundles of reinforcing fibers 404. As described above, the multiple bundles of reinforcing fibers 404 may be woven together to form a 3D woven structure, for example... Figure 4A The woven fabric 400 shown is thus woven to form the first shell structure 201, as... Figure 3A and Figure 3C As shown in the illustration, the woven fabric 400 comprises a plurality of reinforcing fiber bundles 404, which in this embodiment are a plurality of warp fiber bundles 410. When forming the first housing 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 in this embodiment are a plurality of weft fiber bundles 420. When forming the first housing 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 oriented transversely to the warp fiber bundles 410, and in the illustrated embodiment, the warp fiber bundles 410 and the weft fiber bundles 420 are oriented substantially orthogonally to each other. 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 bundle 410 extends in the warp direction Wp, and the weft fiber bundle 420 extends in the weft direction Wf.

[0073] In the depicted embodiment, the woven fabric 400 is a three-dimensional woven fabric, and the woven fabric 400 also includes a thickness direction t. The thickness direction can 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 rows 414 in the weft direction Wf. Figure 4A and Figure 4B The image depicts three warp fiber layers 412, 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 bundle 410 may be kept taut in the warp direction Wp, and one of the weft fiber bundles 420 may pass through or be pulled through it. A shuttle (not shown) may be used to pull one of the weft fiber bundles 420 through the warp fiber bundle 410. The shuttle may pass through the warp fiber bundle 410 in a first direction and then reverse to pass through the warp fiber bundle 410 at different heights in the thickness direction, thereby forming a plurality of weft fiber layers 422 in the thickness direction t. One of the weft fiber bundles 420 may pass continuously through at least a portion of the thickness of the woven fabric 400, and one of the weft fiber bundles 420 may include a portion extending in the thickness direction t, which may be referred to as a turning portion in some embodiments. Therefore, this portion of the weft fiber bundle may be referred to herein as a turning portion 424. The warp fiber bundles 410 may be moved relative to each other to make room for one of the weft fiber bundles 420 to pass through that space. The warp fiber bundles 410 may be moved relative to each other in different ways to produce different patterns. Thus, weaving the fabric 400 involves positioning warp fiber bundles 410 (e.g., keeping the warp fiber bundles 410 taut and stationary), then laying weft fiber bundles 420 (e.g., pulling the weft fiber bundles 420 across and inserting them above and below the corresponding warp fibers 410), and repeating this process until the fabric 400 is formed. The weft fiber bundles 420 may be parallel to each other in both the warp direction Wp and the thickness direction t, and the fabric 400 may include a plurality of weft fiber layers 422 in the thickness direction t and a plurality of weft fiber rows 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-shaped woven fiber bundles). As described above, in forming the first shell structure 201 (such as... Figure 3A and Figure 3C As shown), 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. Different fiber patterns can be used for the interlocking fiber bundles 430. A first interlocking fiber pattern (such as...) Figure 4A and Figure 4BThe diagram shows a positive interlocking pattern, and the interlocking fiber bundle 430 is referred to herein as a positive interlocking fiber bundle 432. In this pattern, the positive interlocking fiber bundle 432 extends substantially in a direction orthogonal to the warp direction Wp, which in the illustrated embodiment is the thickness direction t. Like the weft fiber bundle 420, the interlocking fiber bundle 430 (e.g., the positive interlocking fiber bundle 432) may include a turning portion 434. In the illustrated embodiment, the turning portion 434 of the positive interlocking fiber bundle 432 is positioned to form an alternating pattern between each warp fiber column 414. In the illustrated embodiment, the positive interlocking fiber bundle 432 extends through the thickness of the woven fabric 400 and may be referred to as a full-thickness interlocking fiber bundle, but other thicknesses may be used.

[0076] Figure 4C The second interlocking fiber pattern shown is an angular interlocking pattern, and more specifically a layer-by-layer angular interlocking pattern. Figure 4C From and Figure 4B A similar perspective view captures a cross-sectional view of the woven fabric. The interlocking fiber bundle 430 is referred to in this embodiment as an angled interlocking fiber bundle 436. The angled interlocking fiber bundle 436 does not extend orthogonally through the woven fabric 400, but rather forms an angle relative to the warp direction Wp. In the illustrated embodiment, the angled interlocking fiber bundle 436 extends in an alternating or sinusoidal pattern between adjacent weft fiber layers 422, wherein an angle is formed between adjacent turning portions 434 of the angled interlocking fiber bundle 436. The turning portions 434 of the angled interlocking fiber bundle 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 bundle 436. In other embodiments, the angled interlocking fiber bundle 436 may extend between more than two adjacent weft fiber layers 422. For example, as... Figure 4D As shown, the interlocking fiber bundle 430 is a full-thickness interlocking fiber bundle, which is referred to in this paper as the full-thickness angled interlocking fiber bundle 438. Figure 4D From and Figure 4B A similar 3D view, showing a cross-sectional view of the woven fabric. For clarity, Figure 4C and Figure 4D The meridional fiber bundle 410 is omitted in the text.

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

[0078] Figure 5The manufacture according to embodiments of this disclosure can be used to produce Figure 2 The flowchart illustrates a general process for the composite component of the shell structure shown. 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 out multiple pieces of woven fabric 400 or otherwise positioning multiple pieces of woven fabric 400 relative to each other to form the initial preform.

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

[0080] However, the fabrication of the preform is not limited to woven fabric; it can also be used with reinforcing fiber bundles, which are laid out using other processes to form multiple layers, thereby forming the initial preform in step S20. In this case, step S10 can be omitted, and multiple reinforcing fiber bundles can be laid out to form the first plurality of reinforcing fiber bundles 302 in the arrangement discussed above. Figure 3B ), and the second multiple reinforcing fiber bundles 304 ( Figure 3B ) and the third and multiple reinforcing fiber bundles 306 ( Figure 3B Multiple layers can be laid manually (i.e., by hand) or using an automated process that includes an automated layup system. The automated layup system and corresponding automated process can be, for example, an automated tape layup (ATL) system, an automated fiber layup (AFP) system, a thermoplastic fiber / tape layup (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 die tool. Suitable forming processes may include vacuum forming or other forming processes to give the initial preform a shape. The shaped preform may form a final preform, but optionally, additional machining and manufacturing processes may 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), a matrix material can be injected into the preform in step S40 to generate an infiltrated (or impregnated) preform. When the composite part is a polymer matrix composite, in this step, the polymer and / or resin can be pumped, injected, or otherwise supplied to a mold or cavity to infiltrate or impregnate the dry fibers. For example, when using a resin transfer molding (RTM) process, 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 mentioned above, prepreg fiber bundles can be used to form the preform, and in such embodiments, this step (step S40) can be omitted.

[0083] The method continues in step S50 to cure the infiltrated preform to bond the composite material, and more specifically the matrix, together to form a composite component. The curing process depends on the material and may include coagulating or otherwise hardening the matrix material surrounding the fiber bundles within the preform. For example, when the matrix material is a polymer, curing may include coagulating and chemically crosslinking the polymer chains. Curing the infiltrated preform may include several processes. For example, the infiltrated preform can be thinned and cured by exposing it to the high temperature and pressure of an autoclave. The infiltrated preform may also undergo one or more further processes, such as burn-off cycles and densification processes. Curing step S50 may be combined 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 preformation process at the flange corner, this flange structure and the method of fabricating the flange structure integrate additional and / or reinforcing fiber bundles (a third plurality of reinforcing fiber bundles 306) having a diameter larger than that of other reinforcing fiber bundles within the 3D or 2D woven structure into the flange region. This flange structure and method can be used for integral flanges constructed from various preforms (e.g., three-dimensional (3D) fabrics, two-dimensional (2D) fabrics, or braids), as described in the preceding paragraphs. Furthermore, this flange structure and method can be used for various housing structures, such as fan housings, front frame shells, or both.

[0085] Instead of manually laying additional layers and / or processing sheets, additional and / or larger fiber bundles are integrally woven into the flange region to construct the flange corner (also known as the heel), providing strength to the flange corner and the entire flange. Furthermore, the outer radius surface of the fiber preform in the flange corner region 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. Additionally, at the outer radius of the flange corner, additional fiber bundles and / or fiber bundles with larger diameters can be automatically integrated using three-dimensional (3D) weaving or two-dimensional (2D) weaving or braiding processes.

[0086] This flange structure and method are applicable to typical integral 90-degree upturned flanges, or any structural member constructed from a straight prefabricated member bent to the desired angle (e.g., from 30 to 150 degrees). This flange structure and method improves the manufacturing process for square corners. The square corner manufacturing process also provides a more robust flange structure and better load-bearing capacity for use with fasteners (e.g., bolted joints).

[0087] Further aspects are provided by the following items.

[0088] A preform for fabricating a shell structure, the preform comprising: 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, the diameter or density of the integrally woven or braided fiber bundles being greater than the corresponding diameter or density of the other woven or braided fiber bundles, and wherein the integrally woven or braided fiber bundles are located in regions where the preform is bent to form angular corners, thereby providing strength to the shell structure including the angular corners.

[0089] According to the prefabricated component described in the foregoing clause, the angular corner of the prefabricated component is between 30 and 150 degrees.

[0090] The preform according to 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 according to any of the preceding clauses, wherein 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.

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

[0093] The preform according to any of the preceding clauses, 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.

[0094] According to any of the preceding clauses, the preform is wherein the two-dimensional or 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 near the inner radius surface.

[0095] According to any of the preceding clauses, the number of the third plurality of reinforcing fiber bundles increases with the distance from the inner radius surface to form a triangle with a vertex located near the inner radius surface.

[0096] According to any of the preceding clauses, the diameter of the second plurality of reinforcing fiber bundles located near the outer radius surface of the preform is smaller than the diameter of the third plurality of reinforcing fiber bundles located near the inner radius 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 includes a preform according to any of the preceding clauses, wherein the angular corner forms part of the integral flange; and a polymer matrix material, wherein the plurality of reinforcing fiber bundles of the preform are embedded within the polymer matrix material.

[0098] A three-dimensional woven structure includes 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 the inner radius surface of the three-dimensional woven structure, so as to form triangles with vertices located near the inner radius surface.

[0099] According to the three-dimensional woven structure described in the foregoing clause, 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] According to any of the preceding clauses, the three-dimensional weaving structure wherein the first plurality of reinforcing fiber bundles correspond to weft fibers, and the second plurality of reinforcing fiber bundles and the third plurality of reinforcing fiber bundles correspond to warp fibers.

[0101] The three-dimensional woven structure according to any of the foregoing items, wherein the third plurality of reinforcing fiber bundles are located near the inner radius surface.

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

[0103] According to any of the preceding clauses, the three-dimensional weaving structure wherein the second plurality of reinforcing fiber bundles and the third plurality of reinforcing fiber bundles are substantially parallel to each other.

[0104] According to any of the preceding clauses, the number of the third plurality of reinforcing fiber bundles increases with the distance from the inner radius surface to form a triangle with a vertex located near the inner radius surface.

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

[0106] A turbine engine includes a housing structure having an integral flange, the housing structure comprising a preform and a polymer matrix material. The preform includes a plurality of reinforcing fiber bundles arranged in a two-dimensional woven, three-dimensional woven, or braided structure, wherein the plurality of reinforcing fiber bundles include integrally woven or braided fiber bundles with 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 regions where the preform bends to form angular corners, thereby providing strength to the housing structure including the angular corners, the angular corners forming part of the integral flange, and wherein the plurality of reinforcing fiber bundles of the preform are embedded within the polymer matrix material.

[0107] According to the turbine engine described in the foregoing clause, the angular corner of the preform is between 30 and 150 degrees.

[0108] The turbine engine according to 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 includes thermosetting resin, thermoplastic resin, bismaleimide (BMI) material, or polyimide material, or any combination thereof.

[0110] The turbine engine according to any of the preceding clauses, wherein 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.

[0111] The turbine engine according to 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 according to any of the preceding clauses, 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] The turbine engine according to any of the preceding clauses, wherein the two-dimensional weaving structure, the three-dimensional weaving structure, or the braiding structure defines the outer radius surface and the inner radius surface of the preform, and the integrally woven reinforcing fiber bundle is located near the inner radius surface.

[0114] According to any of the preceding clauses, the number of the third plurality of reinforcing fiber bundles increases with increasing distance from the inner radius surface in order to form a triangle with vertices located near the inner radius surface.

[0115] According to any of the preceding clauses, the diameter of the second plurality of reinforcing fiber bundles located near the outer radius surface of the preform is smaller than the diameter of the third plurality of reinforcing fiber bundles located near the inner radius 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 includes thermosetting resin, thermoplastic resin, bismaleimide (BMI) material, or polyimide material, or any combination thereof.

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

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

[0119] According to the method described in the preceding paragraph, adding the polymer matrix to the two-dimensional or three-dimensional woven structure such that the plurality of reinforcing fiber bundles are embedded in the polymer matrix includes injecting the polymer matrix into a mold containing the two-dimensional or three-dimensional woven structure to fill 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 includes shaping the initial preform to form a shaped preform having the angular corner, the shaped preform having reinforcing fiber bundles of the integral weave arranged in the two-dimensional or three-dimensional weave structure to provide strength for the angular corner.

[0121] The method according to any of the preceding clauses further includes integrally weaving reinforcing fiber bundles, the diameter or density of which is greater than the corresponding diameter or density of other reinforcing fiber bundles in the two-dimensional weave structure or the three-dimensional weave structure; forming a protrusion at the region 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] While the foregoing description pertains to preferred embodiments of the present disclosure, other variations and modifications will be apparent to those skilled in the art and can be made without departing from the present disclosure. Furthermore, even if not explicitly stated above, features described in conjunction with one embodiment of the present disclosure may be used in conjunction with other embodiments.

Claims

1. A prefabricated component for manufacturing a shell structure, characterized in that, The prefabricated component includes: Multiple 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 integrally woven or braided fiber bundles, the diameter or density of which is 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, so as to provide strength and stiffness to the two-dimensional woven structure, the three-dimensional woven structure, or the braided structure in the region of the angular corner of the preform bending to form the shell structure. The integrally woven or braided fiber bundles are located in the region where the preform is bent to form the angular corner of the shell structure, thereby providing strength and stiffness to the angular corner of the shell structure. The number of reinforcing fiber bundles increases with the distance from the inner radius surface to form a triangle with a vertex located near the inner radius surface.

2. The prefabricated component according to claim 1, characterized in that, in, The angle of the angular bend is between 30 and 150 degrees.

3. The prefabricated component according to claim 1, characterized in that, in, 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.

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

5. The preform according to claim 4, characterized in that, in, 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.

6. The precast component 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 precast component according to claim 4, characterized in that, in, The two-dimensional weaving structure, the three-dimensional weaving structure, or the braiding structure defines the outer radius surface and the inner radius surface of the preform, and the integrally woven or braided fiber bundle is located near the inner radius surface.

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

9. A shell structure with an integral flange, characterized in that, include: According to claim 1, the angular corner forms part of the integral flange; and Polymer matrix materials The plurality of reinforcing fiber bundles of the preform are embedded within the polymer matrix material.

10. A turbine engine, characterized in that, include: A shell structure having an integral flange, the shell structure comprising a preform and a polymer matrix material, the preform comprising: Multiple 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 integrally woven or braided fiber bundles, the diameter or density of which is 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, so as to provide strength and stiffness to the two-dimensional woven structure, the three-dimensional woven structure, or the braided structure in the region of the angular corner of the preform forming the corner of the shell structure. The integrally woven or braided fiber bundles are located in the region where the preform bends to form the angular corners of the shell structure, thereby providing strength and stiffness to the angular corners of the shell structure, which form part of the integral flange. The preform contains multiple reinforcing fiber bundles embedded within the polymer matrix material. The number of reinforcing fiber bundles increases with the distance from the inner radius surface to form a triangle with a vertex located near the inner radius surface.

11. The turbine engine according to claim 10, characterized in that, in, The angular corner of the prefabricated component is between 30 and 150 degrees.

12. The turbine engine according to claim 10, characterized in that, in, 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.

13. The turbine engine according to claim 10, characterized in that, in, The polymer matrix material includes thermosetting resins, thermoplastic resins, bismaleimide (BMI) materials, or polyimide materials, or any combination thereof.

14. The turbine engine according to claim 10, characterized in that, in, The plurality of reinforcing fiber bundles include a first plurality of reinforcing fiber bundles, a second plurality of reinforcing fiber bundles, and a third plurality of reinforcing fiber bundles, wherein the third plurality of reinforcing fiber bundles include the integrally woven or braided fiber bundles.

15. The turbine engine according to claim 14, characterized in that, in, 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.

16. The turbine engine according to claim 14, 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.

17. The turbine engine according to claim 14, characterized in that, in, The two-dimensional weaving structure, the three-dimensional weaving structure, or the braiding structure defines the outer radius surface and the inner radius surface of the preform, and the integrally woven or braided fiber bundle is located near the inner radius surface.

18. The turbine engine according to claim 17, characterized in that, in, The diameter of the second plurality of reinforcing fiber bundles located near the outer radius surface of the preform is smaller than the diameter of the third plurality of reinforcing fiber bundles located near the inner radius surface of the preform, so as to form a smaller radius of curvature when forming the angular corner of the preform.

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