Annular shell part for turbine housing and method for manufacturing same

Abstract

The invention relates to an annular shell portion (30) for an annular shell (3) of an aircraft propulsion assembly, the shell portion (30) comprising an annular body (300) extending about an axis (A) and made of a composite material, the shell portion (30) comprising an axial end portion (302) having an annular edge (304) projecting radially outward with respect to said axis, the shell portion (30) comprises a metal insert (310) extending around the axial end portion (302) and connected to the edge (304), the metal insert (310) having an annular groove (318) opening radially outward with respect to the axis; wherein the main body (300) and the edge (304) are made of at least one fibrous preform (P1, P2, P3) obtained by at least partially laying a fold of a composite material on a metal insert (310) and densified by a matrix (M) in order to secure the main body (300) and the metal insert to each other.

Description

Technical Field

[0001] This invention relates to the general field of annular housings for aircraft propulsion components, and more specifically to annular shell portions of such annular housings and methods for manufacturing them. Background Technology

[0002] Specifically, the prior art includes documents FR-A1-3121709 and FR-A1-3009697.

[0003] Aircraft propulsion components typically include a turbine and a nacelle configured to be attached around the turbine.

[0004] The nacelle is typically equipped with multiple fairings that enclose the turbine, allowing access to the turbine in the open position. These fairings are called fan fairings and thrust reverser fairings.

[0005] The turbine comprises multiple annular casings, such as a fan casing extending rearward from the intermediate casing. The intermediate casing is a structural element located between the upstream fan casing and the downstream nacelle fairing. The intermediate casing typically includes an annular casing section (referred to as the intermediate casing section VCI), an inner hub, and angled structural arms that extend radially between the inner hub and the annular casing section to which the structural arms are connected.

[0006] The intermediate housing, including the VCI shell, is typically a machined metal component.

[0007] Figure 1 A common example of an embodiment of an annular shell portion VCI is shown. The annular shell portion 30 includes an annular body 300 extending about a longitudinal axis A and made of a composite material, an axial end portion 302, an annular edge 304 projecting radially outward relative to axis A, and a metal insert 310 extending about the axial end portion 302. The metal insert 310 includes a first annular sidewall 312 and a second annular sidewall 314 connected together by an annular bottom wall 316. Figure 1 In the example shown, the downstream second sidewall 314 forms the annular edge 304 of the annular shell portion 30. These sidewalls 312, 314 and the bottom wall 316 define an annular groove 318 between them. The axial cross-section of the annular groove 318 is generally V-shaped or U-shaped. The annular groove 318 is configured to receive the connecting members of the thrust reverser fairing.

[0008] The fit between the connecting member and the annular groove of the annular shell allows aerodynamic forces to be transmitted from the nacelle toward the turbine during takeoff, flight and landing phases, especially axial forces, and even more so axial reverse thrust when the reverse thrust system equipped to the nacelle fairing is activated.

[0009] exist Figure 1In the annular shell 30 shown, the metal insert 310 is assembled and attached to the axial end 302 by screws V. The disadvantage of this is that it makes the annular shell large and heavy. Furthermore, the manufacture and assembly of such annular shells are complex.

[0010] It is also known that the annular body 300 and the axial end 302 and the annular edge 304 are made entirely of composite materials, and then the metal insert 310 is assembled by adhesive bonding, as shown in the example. Figure 2 As shown. To achieve this, the annular shell 300 is made of two annular fiber preforms P1 and P2, obtained through three-dimensional weaving and densified by a matrix. The first annular fiber preform P1 forms part of the axial end 302 and includes an annular tab P10 forming part of the annular edge 304. The second annular fiber preform P2 forms another part of the axial end 302 and includes an annular arm P20 forming part of the annular rib 306 of the annular shell 300. The annular tab P10 and the annular arm P20 define an annular groove 318 between them. The metal insert 310 is adhered within the annular groove 318.

[0011] therefore, Figure 2 The annular shell 30 shown can be composed of an annular body made of composite material and a metal insert, which are then assembled together by adhesive bonding. This solution also has the following drawbacks: the manufacture and assembly of this annular shell is complex and requires numerous operations that are not largely automated.

[0012] In these different contexts, it is worth noting that the shortcomings of the prior art are overcome by proposing an annular shell portion for an annular housing of an aircraft propulsion assembly, which is more robust and easier to manufacture and assemble. Summary of the Invention

[0013] This invention provides a simple, effective and economical solution to at least some of the above-mentioned problems.

[0014] Therefore, the present invention proposes an annular shell portion for an annular housing of an aircraft propulsion assembly. The annular shell comprises an annular body extending around axis A and made of composite material. The annular shell portion includes an axial end portion having an annular edge that projects radially outward relative to the axis A. The annular shell includes a metal insert that extends around an axial end and abuts an annular edge, the metal insert having an annular groove that opens radially outward relative to the axis A.

[0015] According to the invention, the annular body and the annular edge are made of at least one annular fiber preform, which is obtained by at least partially laying a composite material on a metal insert and densifying it with a matrix to fix the annular body and the metal insert together.

[0016] This solution achieves the aforementioned objective. To achieve this, the present invention proposes connecting (and also forming) the annular body made of composite material and the metal insert into a single component (or in other words, integrally manufactured or made into a single component), and eliminating mechanical fastening devices (such as screws or glue).

[0017] This single-component connection (e.g., made by lay-up) is easy to implement (especially automatically), robust, and not easily damaged during operation. In particular, the annular shell according to the invention proposes to simultaneously form the annular body and annular edge using a composite material by at least partially directly lay-up onto the metal insert. The single-component connection also makes it possible to form an annular shell (especially the annular edge) that is more robust to mechanical stresses exerted, for example, by the fairing of the propulsion assembly. This significantly improves the mechanical strength of the annular shell.

[0018] The present invention also enables a reduction in the number of additional components (such as screws, nuts, bolts, and the adhesive interface between the annular body made of composite material and the metal insert), resulting in a smaller mass and volume of the annular shell.

[0019] Therefore, the advantages of this invention are that it provides very high reliability based on a simple design, and has almost no negative impact on the cost, weight and overall size of the aircraft propulsion components.

[0020] "Plain stacking" refers to the stacking and layering of multiple layers / folds of a composite material (e.g., in the form of strips or bands). Composite materials typically include fibers.

[0021] Two components or parts that are "integrated" or "single" mean that the two components or parts are physically connected to each other and can be inseparable without damaging them.

[0022] The annular shell portion according to the invention may include one or more of the following features, used individually or in combination: - The metal insert includes a first annular sidewall and a second annular sidewall, and an annular bottom wall connecting the first sidewall and the second sidewall, the first sidewall, the second sidewall, and the bottom wall defining the annular groove therebetween. -The annular shell portion also includes an interface layer located between the metal insert and the at least one fiber preform; - The at least one fiber preform includes a first annular fiber preform having an L-shaped axial cross-section, the first fiber preform including: an annular tab forming a portion of the annular edge; and at least a portion of a metal insert, such as a second sidewall forming another portion of the annular edge; - The axial end portion further includes an annular rib extending parallel to and spaced apart from the annular edge, the annular rib extending radially outward relative to the axis A, and the metal insert located between the annular rib and the annular edge; -The at least one fiber preform further includes a second annular fiber preform and a third annular fiber preform. The second fiber preform has a U-shaped axial cross-section, wherein the first annular arm and the second annular arm respectively form at least a portion of the annular rib and at least another portion of the annular edge, and The third fiber preform has an L-shaped axial cross section and includes an annular support leg that forms another part of the annular rib. --The axial cross-section of the metal insert is U-shaped, V-shaped, or T-shaped; --The metal insert is annular and extends around axis A; --The metal insert is sectored into multiple metal insert sectors; --The metal insert sectors are connected together by washers to form a ring-shaped metal insert; --The metal inserts include one to six metal insert sectors; --The metal insert sector has an angular range between 60° and 360°; --Fiber preforms include carbon fibers, ceramic fibers (such as silicon carbide, glass or aramid), polyamide fibers, metal fibers, oxide fibers, or mixtures of at least two of these fibers; --Metal inserts are made of aluminum, steel, or titanium; --The annular shell also includes at least one annular cavity located between the metal insert and at least one fiber preform, the annular cavity being filled with a filler material, such as resin.

[0023] The present invention also relates to an annular housing for an aircraft propulsion assembly, the annular housing comprising an annular shell portion according to the present invention.

[0024] An annular shell can be the intermediate shell of an aircraft propulsion assembly.

[0025] The present invention also relates to an aircraft propulsion assembly comprising a turbine and a nacelle surrounding at least a portion of the turbine. The aircraft propulsion assembly includes an annular shell portion according to one of the features of the invention or an annular housing according to the invention, and further includes a connecting member, such as a connecting member for the nacelle's fairing, attached to an annular groove in the annular shell portion.

[0026] The present invention also relates to a method for manufacturing an annular shell portion according to one of the features of the invention. The method includes the following steps: (a) A metal insert and a layup tool are provided, the metal insert and the layup tool each having an annular shape, the metal insert and the tool each having an inner annular layup surface and at least one annular radial layup surface relative to axis A. (b) To manufacture at least one annular fiber preform by folding the composite material at least partially onto at least one of the inner and radial surfaces of the metal insert and at least partially onto at least one of the inner and radial surfaces of the tool. (c) The at least one fiber preform and the metal insert are densified by co-curing with a matrix to form the at least one fiber preform fixed to the metal insert of the annular shell.

[0027] The method described in this invention simplifies the manufacture of annular shells and makes them more robust. To achieve this, one or more annular fiber preforms are obtained by folding a laminated composite material. Then, during densification and co-curing steps, the one or more annular fiber preforms are directly attached to a metal insert to form the annular shell of this invention.

[0028] In addition, this method is applicable to the automated (e.g., by suitable machinery) or manual manufacture of the annular shell. In particular, the layup can be performed manually or automatically, for example using AFP (Automated Fiber Laying), ATL (Automated Tape Laying), or P&P (Pick & Place) techniques.

[0029] In this application, "fiber preform" refers to a fiber structure obtained by folding a composite material and configured to form at least a portion of the part to be manufactured prior to a densification step.

[0030] "Fiber preform" refers to a fibrous structure configured to form at least a portion of a component to be manufactured after a densification step. Therefore, a fiber preform is formed from a preform that is densified in a resin (and thus embedded in the resin).

[0031] "Co-curing" refers to the simultaneous curing (particularly by heat treatment or heating) of a metal insert (manufactured separately) and one or more annular fiber preforms (at least partially laid on the metal insert) to form a single cured component.

[0032] In this application, the term "curing" will be understood as curing in the literal sense, such as for materials that require curing (e.g., epoxy resins) or for materials that require solidification (e.g., thermoplastic resins).

[0033] The manufacturing method according to the invention may include one or more of the following features, either independently or in combination: - Step (c) includes polymerizing the at least one fiber preform with a resin and converting the resin into a matrix by co-curing heat treatment; - In step (c), the resin is injected into the at least one fiber preform, or - Prior to the layup step (b), the at least one fiber preform is pre-impregnated with resin; - In step (b), the metal insert and the tool are aligned side by side along axis A, and then the first fold of the composite material is laid at least partially on one of the inner surface and the radial surface of the metal insert to form a first fiber blank with an L-shaped axial cross section; Step (b) includes the following sub-steps: (b1) The second fold of the composite material is at least partially laid on the inner and radial surfaces of the metal insert to form a second fiber preform with a U-shaped axial cross-section. (b2) The third fold of the composite material is at least partially laid on the inner and radial surfaces of the tool to form a third fiber preform with an L-shaped axial cross-section. (b3) Align the second and third fiber blanks, which are respectively laid on the metal insert and the tool, side by side along axis A, and (b4) The first fold of the composite material is at least partially laid on the annular inner surface of the second and third fiber preforms and the annular radial surface of the second fiber preform to form a first fiber preform with an L-shaped axial cross section; - Prior to step (b), the method includes step (i): depositing an interface layer at least partially on at least one of the inner surface and radial surface of the metal insert; - The resin is a thermosetting or thermoplastic material, such as epoxy resin, polyepoxide, polyimide, polybismaleimide, polyurethane, polyester or vinyl ester; --The layup step (b) can be performed manually or automatically using a suitable machine; --The composite folding includes glass fiber, carbon fiber, aramid fiber, polyamide fiber, ceramic fiber (such as silicon carbide, glass or aramid), metal fiber, oxide fiber or a mixture of at least two of these fibers. Attached Figure Description

[0034] The invention will be better understood from the following description, given by way of non-limiting example and with reference to the accompanying drawings, and other details, features and advantages of the invention will become more apparent, in which: - Figure 1 This is a schematic half-view of an axial cross-section of an annular shell portion according to a first embodiment of the prior art, the annular shell portion including a metal insert that is attached to an annular body made of composite material by screws; - Figure 2 This is a schematic half-view of the axial cross-section of an annular shell according to a second embodiment of the prior art, the annular shell including a metal insert bonded to an annular body made of a composite material obtained by three-dimensional weaving of filaments; - Figure 3 This is a schematic half-view of the axial cross-section of an aircraft propulsion assembly according to the present invention; - Figure 4 It comes from Figure 3 A schematic perspective view of the annular casing of the turbine of the aircraft propulsion assembly shown; - Figure 5a yes Figure 4 A schematic half-view of the axial cross-section of a first example of the annular shell portion of the annular shell and the connecting member of the aircraft propulsion assembly. - Figure 5b yes Figure 5a A schematic half-view of the axial cross-section of the modified annular shell shown; - Figure 6 yes Figure 4 A schematic half-view of the axial cross-section of a second example of the annular shell portion of the annular shell; - Figure 7 yes Figure 4 A schematic half-view of the axial cross-section of the third example of the annular shell portion of the annular shell; - Figure 8 yes Figure 4 A schematic half-view of the axial cross-section of the fourth example of the annular shell portion of the annular shell; - Figure 9 This is a block diagram of a method for manufacturing the annular shell portion of the present invention; - Figure 10 This schematically illustrates how to achieve the desired result by folding and stacking the composite material onto a metal insert. Figure 5aThe first example shown is a ring-shaped shell used to manufacture fiber preforms; - Figure 11 This schematically illustrates how to achieve the desired result by folding and stacking the composite material onto a metal insert. Figure 6 The second example shown is a ring-shaped shell used to manufacture multiple fiber preforms.

[0035] Elements that have the same function in different embodiments have the same reference numerals in the drawings. Detailed Implementation

[0036] By convention, in the following description, the terms "longitudinal" and "axial" refer to the orientation of a structural element extending in a direction along a longitudinal axis (such as the longitudinal axis of an aircraft propulsion assembly). The terms "radial" or "vertical" refer to the orientation of a structural element extending in a direction perpendicular to the longitudinal axis. The terms "inner" and "outer," as well as "internal" and "external," are used for positioning relative to the longitudinal axis. Thus, a structural element extending along a longitudinal axis includes an inner surface facing the longitudinal axis and an outer surface opposite the inner surface of the structural element. Similarly, the terms "upstream" and "downstream" are defined relative to the direction of gas flow in an aircraft propulsion assembly.

[0037] Figure 1 and Figure 2 As described in the background section of this application, and Figure 1 and Figure 2 An example of an annular shell portion of an annular housing for an aircraft propulsion assembly, according to the prior art, is shown.

[0038] The present invention is applied in a general and non-limiting manner, for example in... Figure 3 The aircraft propulsion assembly 10 is shown in the image.

[0039] The aircraft propulsion assembly 10 includes a turbine 1 and a nacelle 2 surrounding at least a portion of the turbine 1.

[0040] The aircraft propulsion assembly 10 can extend along the longitudinal axis X.

[0041] The nacelle 2 may extend along a longitudinal axis that may correspond to axis X. The nacelle 2 may include one or more fairings. Each fairing of the nacelle 2 may be an integrally formed annular fairing or a semi-cylindrical fairing articulated together.

[0042] refer to Figure 3 The nacelle 2, along the gas flow direction F from upstream to downstream, includes an annular air inlet structure 2a, a fan fairing 2b, and a thrust reverser fairing 2c.

[0043] The thrust reverser fairing 2c can define an annular channel 20 for the secondary airflow F2 by means of an annular inner skin 21 and an annular outer skin 22. In particular, the outer skin 22 can be formed by the thrust reverser fairing 2c, and the inner skin 21 can be formed by an annular shell (such as the annular shell of the intermediate shell 3 of the turbine 1).

[0044] The turbine 1 can also extend about a longitudinal axis that corresponds to axis X. The turbine 1 can be configured to be attached to a structure of the aircraft (e.g., an aircraft wing or along the aircraft fuselage).

[0045] Turbine 1 typically includes multiple modules, which, from upstream to downstream along the gas flow direction F, include a fan 1a, one or more compressor stages (e.g., low-pressure compressor 1b and high-pressure compressor 1c), a combustion chamber 1d, one or more turbine stages (e.g., high-pressure turbine 1e and low-pressure turbine 1f), and possibly exhaust nozzles.

[0046] Turbine 2 can be a two-flow turbojet engine. In this configuration, a fan 1a, typically located at the front of turbine 1, delivers a compressed air flow that is divided into two concentric annular flows: a primary air flow F1 and a secondary air flow F2 extending around the primary air flow F1.

[0047] Turbine 1 may include a plurality of annular housings, such as at least one of the following: - Fan housing 4 extending around fan 1a - Intermediate housing 3, which is located in the rest of the turbine 1 (i.e., in Figure 3 The example shown extends upstream of the low-pressure compressor 1b), and - Central housing 5, which causes the hub 32 of intermediate housing 3 to extend downstream, and the central housing 5 is connected to intermediate housing 3.

[0048] The ducted turbine 1 can be a turbojet engine or a turboprop engine.

[0049] exist Figure 3 In the example shown, the central housing 5 may extend around the compressor stages 1a, 1b, combustion chamber 1d, turbine stages 1e, 1f, and possibly the exhaust nozzle.

[0050] The intermediate housing 3 may include an annular housing portion 30, a hub portion 32 referred to as the interior relative to the axis X, and structural arms 34 distributed at an angle, which extend radially between the hub portion 32 and the annular housing portion 30 connected to the structural arms. The annular housing portion 30 extends around the hub portion 32.

[0051] refer to Figure 4 The annular shell portion 30 includes: -A ring-shaped main body 300 extending around axis A. - An axial end portion 302, the axial end portion 302 having an annular edge 304 projecting radially outward relative to axis A, and - Metal insert 310, which extends around the axial end 302 and abuts the annular edge 304.

[0052] Axis A can extend longitudinally and can substantially correspond to the longitudinal axis X of the aircraft propulsion assembly 10.

[0053] For example, the annular housing 30 may also include a radial flange 301 for attachment to the fan housing 4. The radial flange 301 may be annular and positioned relative to the axial end portion 302.

[0054] exist Figure 4 In the example shown, the annular body 300, which forms the basic structural part of the annular shell 30, includes a radial flange 301, a shell shaft 300a having a cylindrical shape and a circular cross-section, an axial end 302, and an annular edge 304 from upstream to downstream (relative to the gas flow direction F). The radial flange 301, the shell shaft 300a, and the axial end 302 with the annular edge 304 can be a single component.

[0055] The annular body 300 is made of composite material. The shell shaft 300a, the axial end 302 with an annular edge 304, and the possible radial flange 301 can be made of composite material.

[0056] The metal insert 310 includes an annular groove 318 that opens radially outward relative to axis A. The axial cross-section of the annular groove 318 may be generally U-shaped or V-shaped. The annular groove 318 may be configured to receive the connecting member 24 of the aircraft propulsion assembly 10 (such as the connecting member of the fairing of the nacelle 2, particularly the connecting member of the thrust reverser fairing 2c).

[0057] exist Figures 5a to 8 An example of the metal insert 310 is shown in a non-limiting manner.

[0058] Advantageously, the metal insert 310 may be annular and extend around axis A (particularly on and around axial end 302). The metal insert 310 may be integrally formed and formed as a single piece, or sectored into multiple metal insert sectors.

[0059] For example, the metal insert 310 may include one to six metal insert sectors. Preferably, the metal insert 310 may be formed by two metal insert sectors.

[0060] The metal insert sector can have an angular range between 60° and 360° (relative to axis A). In this way, when the metal insert 310 is formed by a single sector and is annular in shape, the angular range can be 360°. When the metal insert 310 is formed by two metal insert sectors, the angular range can be 180°. When the metal insert 310 is formed by six metal insert sectors, the angular range can be 60°. The metal insert 310 can be made of aluminum, steel, or titanium.

[0061] In the axial cross-section, the metal insert 310 can be U-shaped or V-shaped (e.g., Figures 5a to 7 As shown), T-shaped (as shown) Figure 8 (as shown), or any other so-called hollow shape that can be adapted (or otherwise supplemented) to the shape of the axial end 302 of the annular shell, in particular.

[0062] The metal insert 310 may include a first annular sidewall 312, a second annular sidewall 314, and an annular bottom wall 316. The bottom wall 316 connects the first sidewall 312 and the second sidewall 314 to each other. Figure 5a In the example shown, the first sidewall 312 and the second sidewall 314 extend radially outward relative to axis A. The bottom wall 316 may extend axially along axis A. The first sidewall 312, the second sidewall 314, and the bottom wall 316 define an annular groove 318 between them.

[0063] The first sidewall 312, the second sidewall 314, and the bottom wall 316 can be integrally formed (i.e., a single component).

[0064] The sectorized metal insert 310 may include washers 319 configured to connect the metal insert sectors together. Washers 319 may be silicone adhesive. As an example, washers 319 may be disposed in an annular recess 318, particularly on and around the annular bottom wall 316 of the metal insert sector.

[0065] The metal insert 310 (particularly the bottom wall 316) may include an inner annular surface 310c (relative to axis A). The metal insert 310 (particularly each of the first sidewall 312 and the second sidewall 314) may include a first radial annular surface 310a and a second radial annular surface 310b (relative to axis A). Preferably, these radial surfaces 310a, 310b and the inner surface 310c are spaced apart from the annular groove 318.

[0066] The second sidewall 314 (particularly the second radial surface 310b) may abut against and / or correspond to a portion of the annular edge 304. In this way, the annular edge 304 is reinforced to withstand the mechanical stresses exerted by the fairing of the nacelle 2 during operation.

[0067] The bottom wall 316 (particularly the inner surface 310c) may extend around at least a portion of the axial end 302.

[0068] exist Figure 5a In the example shown, the first sidewall 312 may have a first diameter D 312 First diameter D 312 The second diameter D is smaller than the second sidewall 314. 314 According to the variant not shown in the figure, the first diameter D 312 It can be equal to the second diameter D 314. First diameter D 312 Second diameter D 314 Measured in a plane perpendicular to axis A.

[0069] One feature of the present invention is that the annular body 300 and the annular edge 304 are made of at least one annular fiber preform P1, P2, P3. The one or more fiber preforms P1, P2, P3 are obtained by at least partially laying down a composite material onto the metal insert 310 (hereinafter simply referred to as "lay-down") and densified by a matrix M. In this way, the annular body 300 is fixed to the metal insert 310. In other words, the annular body 300 and the annular edge 304, as well as the metal insert 310, made of composite material, are single components and are integrally manufactured.

[0070] One or more fiber preforms P1, P2, P3 may each have a U-shaped or L-shaped axial cross section. The dimensions (axial length, radial height, etc.) of the U-shape and L-shape of the fiber preforms P1, P2, P3 may vary according to different embodiments of the invention described below.

[0071] The annular shell 30 may also include an interface layer 308 located between the metal insert 310 and the fiber preforms P1, P2. This interface layer 308 may extend annularly about axis A. The interface layer 308 may be made of an elastomer. The interface layer 308 can withstand differential expansion between the metal insert 310 and the fiber preforms P1, P2, particularly thermal expansion. These differential expansions may occur during manufacturing (e.g., during the resin injection step in the mold) or as part of manufacturing. The interface layer 308 also enables protection of the annular body 300 and annular edge 304, made of composite materials, from possible galvanic corrosion, particularly when the metal insert 310 is made of aluminum.

[0072] The composite folding of one or more fiber preforms P1, P2, P3 may include glass fiber, carbon fiber, aramid fiber, polyamide fiber, ceramic fiber (such as silicon carbide, glass or aramid), metal fiber, oxide fiber, or a mixture of at least two of these fibers.

[0073] This application will now refer to Figures 5a to 8 Various possible configurations of the annular shell portion 30 of the present invention are described, and in particular, various possible configurations of one or more fiber preforms P1, P2, P3.

[0074] Figure 5a and Figure 5b A first embodiment of the annular shell portion 30 is shown, wherein the annular body 300 and the annular edge 304 (as referenced above) Figure 3 and Figure 4 The first fiber preform (P1) can be made from a first annular fiber preform P1. The axial cross-section of the first fiber preform P1 can be approximately L-shaped. The first fiber preform P1 can have an axial length L measured along axis A. P1 .

[0075] The first fiber preform P1 may include a cylindrical segment P100 having a circular cross-section, the cylindrical segment P100 extending along axis A and configured to form at least a portion of an annular body 300 (such as a shell shaft 300a and possibly a radial flange 301 and an axial end 302).

[0076] The cylindrical segment P100 may include an annular end segment P102, which is configured to form at least a portion of the axial end 302. Figure 5a and Figure 5b In the example shown, the end section P102 may form at least a portion of the axial end 302 of the annular shell portion 30. In particular, the end section P102 may abut against the inner surface 310c. In this way, the bottom wall 316 may extend around the end section P102.

[0077] The first fiber preform P1 may include an annular tab P10. In an example, the annular tab P10 may extend radially outward relative to axis A. In particular, the annular tab P10 may abut against the second sidewall 314 (especially at the height of the second side surface 310b). The annular tab P10 is configured to form part of the annular edge 304 of the annular shell portion 30, and a metal insert (especially the second sidewall 314) forms another part of the annular edge 304. In this way, the annular tab P10 and the second sidewall 314 may together form the annular edge 304.

[0078] The annular protrusion P10 may have a third diameter D measured in a plane perpendicular to axis A (or axis X). P10 .exist Figure 5a and Figure 5b In the example shown, the third diameter D P10 The second diameter D, similar to the second sidewall 314 314 In the variant not shown in the figure, the third diameter D P10 The second diameter D can be smaller than the second sidewall 314. 314 In another variation, the third diameter D P10 It can be similar to the first diameter D of the first sidewall 312 312 .

[0079] Therefore, the first fiber preform P1 can be a single component and integrally formed with the metal insert 310.

[0080] refer to Figure 5b The annular shell portion 30 of the first embodiment may include an interface layer 308 located between at least a portion of the first fiber preform P1 and the metal insert 310. This interface layer 308 may be formed, on the one hand, between the bottom wall 316 (particularly the inner surface 310c) and at least a portion of the first fiber preform P1 (particularly the end segment P102), and on the other hand, between the second sidewall 314 (particularly the second radial surface 310b) and at least a portion of the annular tab P10. In this way, the interface layer 308 may be located both between the second radial surface 310b and the annular tab P10, and between the inner surface 310c and the end segment P102.

[0081] In the annular shell portion 30 of the first embodiment, the axial cross-section of the metal insert 310 is approximately U-shaped. The axial cross-section of the annular groove 318 is approximately V-shaped.

[0082] Figure 6 A second embodiment of the annular shell portion 30 is shown, which differs from the annular shell portion 30 of the first embodiment in that it has additional annular ribs 306 and multiple additional fiber preforms P2, P3 to form an annular body 300 and annular edge 304.

[0083] In fact, the annular shell portion 30 of the second embodiment also includes the annular rib 306, which extends parallel to and is spaced apart from the annular edge 304. The annular rib 306 protrudes radially outward relative to axis A. In this configuration, the metal insert 310 is located between the annular rib 306 (particularly the first annular arm P22 of the second fiber preform P2) and the annular edge 304 (particularly the second annular arm P24 of the second fiber preform P2). Therefore, the annular rib 306 can abut against the first sidewall 312 (particularly on the first radial surface 310a), and the annular edge 304 can abut against the second sidewall 314 (particularly on the second radial surface 310b).

[0084] The annular rib 306 may have a fourth diameter D 306 The fourth diameter D 306 The fifth diameter D is less than or equal to the annular edge 304. 304 Fourth diameter D 306 Can be with the first diameter D 312 same( Figure 6 (or smaller than the first diameter D) 312 Fifth diameter D 304 Can be used with the second diameter D 314 same( Figure 6 (or smaller than the second diameter D) 314 Fourth diameter D 306 and the fifth diameter D 304 Measured in a plane perpendicular to axis A.

[0085] Furthermore, the annular body 300 and annular edge 304 of the second embodiment can be made from the first fiber preform P1 (as referenced above). Figure 5a and Figure 5b The aforementioned) and also made of the second annular fiber preform P2 and the third annular fiber preform P3.

[0086] The position of the first fiber preform P1 in the annular shell portion 30 in the second embodiment differs from that in the first embodiment. In the second embodiment, the second fiber preform P1 and the third fiber preform P2 may extend side by side axially (or in other words, side by side adjacent) and radially around the first fiber preform P1 (particularly the cylindrical section P100 and possibly the end section P102 for the second fiber preform P2).

[0087] The axial cross-section of the second fiber preform P2 can be approximately U-shaped. The second fiber preform P2 can have a second axial length L measured along axis A. P2 The second axial length L P2 It can be less than the first axial length L P1 .

[0088] The second fiber preform P2 may include a first annular arm P22 and a second annular arm P24, the first annular arm P22 and the second annular arm P24 being configured to form at least a portion of an annular rib 306 and at least a portion of an annular edge 304, respectively.

[0089] The first annular arm P22 and the second annular arm P24 may extend radially outward relative to axis A, respectively. The first annular arm P22 may abut against the first sidewall 312 (particularly on the first radial surface 310a). The second annular arm P24 may abut against the second sidewall 314 (particularly on the second radial surface 310b).

[0090] The first ring arm P22 and the second ring arm P24 may each have a sixth diameter D, which can be measured in a plane perpendicular to axis A. P22 and the seventh diameter D P24 First diameter D 312 Can be used with the sixth diameter D P22 same( Figure 6 (or less than the sixth diameter D) P22 Second diameter D 314 Can be compared with the seventh diameter D P24 same( Figure 6 (or less than the seventh diameter D) P24 .

[0091] The second fiber preform P2 may further include a bottom P202 that connects the first annular arm P22 and the second annular arm P24 together. The bottom P202 may extend axially along axis A. The bottom P202 may be configured to form at least a portion of the axial end portion 302 of the annular shell portion 30, and another portion of the axial end portion 302 is formed by the end section P102 of the first fiber preform P1.

[0092] Advantageously, the metal insert 310 can be at least partially covered by the second fiber preform P2. In particular, the second fiber preform P2 (by means of the first annular arm P22 and the second annular arm P24 and the bottom P202) covers the radial surfaces 310a, 310b and the inner surface 310c of the metal insert 310.

[0093] The axial cross-section of the third fiber preform P3 can be approximately L-shaped. This third fiber preform P3 can have a third axial length L measured along axis A. P3 The third axial length L P3 It can be less than the first axial length L P1 The third axial length L P3 It can be greater than the second axial length L P2 .

[0094] The third fiber preform P3 may include a cylindrical portion P300 having a circular cross-section, which extends along axis A and is configured to form at least one other portion of the annular body 300 (such as a shell shaft 300a and possibly a radial flange 301). The cylindrical portion P300 may extend at least partially around the cylindrical segment P100.

[0095] The third fiber preform P3 may include an annular support leg P30. Figure 6 In the example shown, the annular support leg P30 may extend radially outward relative to axis A. Specifically, the annular support leg P30 may abut against the first annular arm P22. The annular support leg P30 may be configured to form another portion of the annular rib 306 of the annular shell portion 30. In this configuration, the first annular arm P22 (possibly with the first sidewall 312) forms part of the annular rib 306, and the annular support leg P30 forms another portion of the annular rib 306.

[0096] The annular support leg P30 can have an eighth diameter D measured in a plane perpendicular to axis A (or axis X). P30 .exist Figure 6 In the example shown, the eighth diameter D P30 Similar to the first diameter D 312 and the sixth diameter D P22 .

[0097] Therefore, the first fiber preform P1, the second fiber preform P2, and the third fiber preform P3 can be a single component and integrally formed with the metal insert 310.

[0098] exist Figure 6 In the example shown, and in a non-limiting manner, the annular shell portion 30 of the second embodiment may include an interface layer 308 located between at least a portion of the second fiber preform P2 and the metal insert 310. This interface layer 308 may be formed on: - Between the bottom wall 316 and the bottom P202 of the second fiber preform P2, - Between the first sidewall 312 and the first annular arm P20 of the second fiber preform P2, and - Between the second sidewall 314 and the second annular arm P24 of the second fiber preform P2.

[0099] In this way, the interface layer 308 can be located between the radial surfaces 310a, 310b and the inner surface 310c of the metal insert 310 and the annular arms P22, P24 and the bottom P202 of the second fiber preform P2.

[0100] Figure 7A third embodiment of the annular shell portion 30 is shown, which differs from the annular shell portion 30 of the second embodiment in that it has a metal insert 310.

[0101] In practice, the metal insert 310 of the third embodiment may have one of a first sidewall 312 and a second sidewall 314, which is inclined relative to a corresponding one of the annular arms P22, P24 to form an annular cavity between the sidewall and the corresponding annular arm. This annular cavity may be filled with a filler material, such as a polymeric resin forming a densified matrix M. The resin may be a thermosetting or thermoplastic material, for example, based on epoxy resin, polyepoxide, polyimide, polybismaleimide, polyurethane, polyester, or vinyl ester.

[0102] exist Figure 7 In the example shown, the first sidewall 312 is inclined relative to the first annular arm P22. Therefore, the first sidewall 312 may include a first radial end 312a extending radially outward (relative to axis A) and a second radial end 312b opposite to the first radial end 312a. The first radial end 312a is adjacent to the first annular arm P22, and the second radial end 312b is away from the first annular arm P22.

[0103] Figure 8 A fourth embodiment of the annular shell portion 30 is shown, which differs from the annular shell portions 30 of the first, second, and third embodiments in that it has a metal insert 310. In particular, the axial cross-section of the metal insert 310 is T-shaped.

[0104] Figure 8 The metal insert 310 includes a first annular sidewall 312 and a second annular sidewall 314, an annular bottom wall 316 (as described above), and an axial tab 317. The axial tab 317 may be an axial extension of the annular bottom wall 316. The axial tab 317 may extend between a first end and a second end opposite to the first end. The first end may be connected to the annular bottom wall 316 and the second annular sidewall 314. The second end may be free. At least one section of the axial tab 317 (particularly the second end) may be thickened.

[0105] exist Figure 8 In the example shown, the first annular sidewall 302 may abut against the annular edge 304 of the annular body 300. Alternatively, not shown in the figure, the second annular sidewall 314 may abut against the annular edge 304, and the axial tab 317 may be connected to the first annular sidewall 312 and the annular bottom wall 316. According to another variation not shown, the annular edge 304 is optional, and when the axial cross-section of the metal insert 310 is T-shaped, the annular edge 304 may not be present in the annular shell portion 30.

[0106] in addition, Figure 8 The metal insert 310 is sectored and therefore includes a washer 319, which allows the metal insert sectors to be joined together to form an annular component. In a non-limiting manner, the washer 319 is positioned at the height of the axial tab 317. Specifically, the washer 319 may be in the form of an annular strip to which the axial tab 317 of the metal insert sector is adhered.

[0107] As described with reference to the first embodiment of the annular shell, according to Figure 8 The example annular body 300 can be made from a first annular fiber preform P1.

[0108] This application now describes a method for manufacturing the annular shell portion 30 of the present invention, wherein the successive steps of the method are, for example, in Figure 9 Overview. Optional steps are shown in dashed lines.

[0109] According to the present invention, the method includes the following steps: (a) Provides a metal insert 310 and a layup tool O, (b) At least one fiber preform T1, T2, T3 is manufactured by folding the composite material at least partially onto the metal insert 310 and at least partially onto the tool O. (c) The at least one fiber preform T1, T2, T3 and the metal insert 310 are densified by the matrix M through co-curing to manufacture at least one fiber preform P1, P2, P3 fixed to the metal insert 310 of the annular shell 30.

[0110] In step (a), the metal insert 10 may be integrally formed or sectored. The metal insert sectors may be connected together, particularly by means of washers 319, to form an annular component.

[0111] Therefore, the metal insert 310 and the tool O can each have an annular shape.

[0112] Tool O has an inner annular surface O i and lateral annular surface O l Inner annular surface O i and lateral annular surface O l Each of the elements is configured to undergo a piling step (b). The lateral surface O l Extending radially outward (relative to axis A). The first radial surface 310a, the second radial surface 310b, and the inner surface 310c of the metal insert 310 are respectively configured to undergo the layup step (b).

[0113] In step (b), the lay-up is at least partially applied to at least one of the inner surface 310c and radial surfaces 310a, 310b of the metal insert 310, and to the inner surface O of the tool. i The above will be carried out.

[0114] The tiling step (b) can be performed in different ways.

[0115] Figure 10 A first example of an embodiment of step (b) is shown, wherein the metal insert 310 and the tool O can be aligned side-by-side axially along axis A. Specifically, the lateral surface O of the tool O... l The first radial surface 310a of the metal insert 310 may be adjacent to the axis A. Then, the first fold of the composite material may at least partially overlap (partially overlap simultaneously) the inner surface O of the tool. i The fiber is laid on, and at least partially on, at least one of the inner surface 310c and radial surfaces 310a, 310b of the metal insert 310 to form a first annular fiber preform T1 with an L-shaped axial cross-section. The first fiber preform T1 is configured to form a first fiber preform P1 (particularly after step (c)).

[0116] In particular, the inner surface O can be laid up by using the first fold of the composite material. i The inner surface O is formed by the second radial surface 310c and the second radial surface 310b to achieve the L-shaped axial cross-section of the first fiber blank T1. Therefore, the inner surface O... i The layup of 310c enables the formation of cylindrical segment P100 and end segment P102 (especially after densification step (c)), and the layup of the second radial surface 310b enables the formation of annular tabs P10 (especially after step (c)).

[0117] Figure 11 A second example of an embodiment of step (b) is shown, which may include the following sub-steps: (b1) The second fold of the composite material is at least partially laid on the inner surface 310c and radial surfaces 310a, 310b of the metal insert 310 to form a second annular fiber preform T2, the second annular fiber preform T2 having a U-shaped axial cross section and being configured to form a second fiber preform P2 (especially after step (c)). (b2) Lay the third fold of the composite material at least partially on the inner surface O of tool O. i and lateral surface O l Above, to form a third annular fiber preform T3, which has an L-shaped axial cross section and is configured to form a third fiber preform P3 (especially after step (c)). (b3) Align the second fiber blank T2 and the third fiber blank T3, which are respectively laid on the metal insert 310 and the tool O, side by side along axis A, and (b4) The first fold of the composite material is at least partially laid over the inner annular surface T2 of the second fiber preform T2. i and the inner annular surface T3 of the third fiber blank T3 i and the radial annular surface T2 of the second fiber blank T2 r The first fiber blank T1 is formed with an L-shaped axial cross-section.

[0118] Step (b3) enables the second fiber preform T2 and the third fiber preform T3 to be assembled and aligned along axis A, so as to form the inner surface T2 of the second fiber preform T2. i and radial surface T2 r On the other hand, it forms the internal surface T3 of the third fiber blank T3. i .exist Figure 11 In the example shown, the inner surface T2 i T3 i It can extend longitudinally along axis A, and radial surface T2 i These internal surfaces T2 can extend radially outward relative to axis A. i T3 i and radial surface T2 r They are respectively constructed to undergo the tiling step (b4).

[0119] Specifically, the U-shape of the second fiber blank T2 can be achieved by using a second fold of the composite material to lay up the radial surfaces 310a, 310b and the inner surface 310c of the metal insert. This makes it possible to form the first annular arm P22 and the second annular arm P24 as well as the bottom P202 (especially after step (c)).

[0120] The inner surface O of tool O can be laid up by using the third fold of the composite material. i and lateral surface O l To achieve the L-shaped axial cross section of the third fiber blank T3. This makes it possible to form (especially simultaneously) the cylindrical part P300 (especially after step (c)) and the annular leg P30 (especially after step (c)).

[0121] The L-shaped axial cross section of the first fiber preform T1 can be achieved by using the first fold of the composite material to lay (especially simultaneously lay) the inner surfaces of the second fiber preform T2 and the third fiber preform T3. This makes it possible to simultaneously form the cylindrical section P100 and the end section (especially after step (c)), and simultaneously form the annular tab P10 (especially after step (c)).

[0122] The tile-layout steps (b), particularly steps (b1), (b2), and (b4), can be performed manually or automatically using a suitable machine. For example, automatic tile-layout can be performed using one of the following technologies: AFP, ATL, or P&P.

[0123] As described above, the first, second, and third folds of the composite material may respectively include glass fiber, carbon fiber, aramid fiber, polyamide fiber, ceramic fiber (such as silicon carbide, glass, or aramid), metal fiber, oxide fiber, or a mixture of at least two of these fibers.

[0124] Step (c) enables one or more fiber preforms T1, T2, T3 to be directly co-molded (and co-injected during composite folding and drying, i.e., without resin pre-impregnation) onto a metal insert (possibly together with interface layer 308) in a single curing step and cycle (i.e., by co-curing).

[0125] "Co-molding" or "co-injection" refers to a single step in a manufacturing process used to simultaneously mold multiple parts or inject materials.

[0126] Step (c) may include polymerizing one or more fiber preforms T1, T2, T3 with a resin and converting the resin into a matrix by co-curing heat treatment (or other heating). In this way, the resin hardens by fixing the formed one or more fiber preforms P1, P2, P3 to the metal insert 310.

[0127] In step (c), resin can be injected, particularly into a manufacturing mold, to polymerize and cure one or more fiber preforms T1, T2, T3 into corresponding one or more fiber preforms P1, P2, P3. Alternatively, the folding of the composite material constituting one or more fiber preforms T1, T2, T3 can be pre-impregnated with resin, for example, before the layup step (b).

[0128] As mentioned above, the resin can be a thermosetting or thermoplastic material, such as epoxy resin, polyepoxide, polyimide, polybismaleimide, polyurethane, polyester, or vinyl ester.

[0129] Prior to step (b), the manufacturing method may include step (i): depositing an interface layer 308 at least partially on at least one of the inner surface 310c and radial surfaces 310a, 310b of the metal insert 310. As an example, the interface layer 308 may be deposited to at least partially cover the inner surface 310c and the second radial surface 310b. Figure 5b ), and may cover the first radial surface 310a ( Figure 6 ).

[0130] As described above, the interface layer 308 can be made of an elastomer.

Claims

1. An annular shell portion (30) for an annular shell (3) of an aircraft propulsion assembly (10). The annular shell (30) includes an annular body (300) extending around an axis (A) and made of composite material. The annular shell portion (30) includes an axial end portion (302) having an annular edge (304) that projects radially outward relative to the axis (A). The annular shell portion (30) includes a metal insert (310) that extends around the axial end portion (302) and abuts the annular edge (304), the metal insert (310) having an annular groove (318) that opens radially outward relative to the axis (A). Its features are, The annular body (300) and the annular edge (304) are made of at least one annular fiber preform (P1, P2, P3), which is obtained by folding a composite material at least partially overlaying it onto the metal insert (310) and densifying it with a matrix (M) to secure the annular body (300) and the metal insert (310) together.

2. The annular shell portion according to claim 1, characterized in that, The metal insert (310) includes a first annular sidewall (312) and a second annular sidewall (314) and an annular bottom wall (316) connecting the first sidewall and the second sidewall (312, 314), the first sidewall and the second sidewall (312, 314) and the bottom wall (316) defining the annular groove (318) therebetween.

3. The annular shell portion according to claim 1 or 2, characterized in that, The annular shell (30) further includes an interface layer (308) located between the metal insert (310) and the at least one fiber preform (P1, P2).

4. The annular shell portion according to any one of claims 1 to 3, characterized in that, The at least one fiber preform (P1, P2, P3) includes a first annular fiber preform (P1) having an L-shaped axial cross-section, the first fiber preform (P1) including: an annular tab (P10) forming a portion of the annular edge (304); and at least a portion of the metal insert (310), such as a second sidewall (314), forming another portion of the annular edge (304).

5. The annular shell portion according to any one of claims 1 to 4, characterized in that, The axial end portion (302) further includes an annular rib (306) extending parallel to and spaced apart from the annular edge (304), the annular rib (306) extending radially outward relative to the axis (A), and the metal insert (310) located between the annular rib (306) and the annular edge (304).

6. The annular shell portion according to claim 5, characterized in that, The at least one fiber preform (P1, P2, P3) further includes a second annular fiber preform (P2) and a third annular fiber preform (P3). The second fiber preform (P2) has a U-shaped axial cross-section, wherein the first annular arm (P22) and the second annular arm (P24) respectively form at least a portion of the annular rib (306) and at least another portion of the annular edge (304), and The third fiber preform (P3) has an L-shaped axial cross section and includes an annular leg (P30) forming another part of the annular rib (306).

7. An annular housing (3) for an aircraft propulsion assembly (10), comprising an annular housing portion (30) according to any one of the preceding claims.

8. An aircraft propulsion assembly (10), comprising a turbine (1) and a nacelle (2) surrounding at least a portion of said turbine (2), characterized in that, The aircraft propulsion assembly includes an annular shell portion (30) according to any one of claims 1 to 6 or an annular shell (3) according to claim 7, and the aircraft propulsion assembly (10) further includes a connecting member (24), such as a connecting member of the fairing (2c) of the nacelle (2), the connecting member being attached to an annular groove (318) in the annular shell portion (30).

9. A method for manufacturing an annular shell portion (30) according to any one of claims 1 to 6, characterized in that, The method includes the following steps: (a) Provides a metal insert (310) and a layup tool (O), the metal insert and the layup tool each having an annular shape, the metal insert (310) and the tool (O) each having an annular inner layup surface (310c, O). i ) and at least one annular radially stacked surface (310a, 310, O) relative to the axis (A). r ), (b) By folding the composite material at least partially over at least one of the inner surface (310c) and the radial surface (310a, 310b) of the metal insert (310) and at least partially over the inner surface (O) of the tool (O). i ) and the radial surface (O r At least one of the following can be used to manufacture at least one annular fiber preform (T1, T2, T3). (c) The at least one fiber preform (T1, T2, T3) and the metal insert (310) are densified by a matrix (M) through co-curing to form the at least one fiber preform (P1, P2, P3) fixed to the metal insert (310) of the annular shell (30).

10. The manufacturing method according to claim 9, characterized in that, Step (c) includes polymerizing the at least one fiber preform (T1, T2, T3) with resin and converting the resin into a matrix by co-curing heat treatment.

11. The manufacturing method according to claim 10, characterized in that, In step (c), the resin is injected into the at least one fiber preform (T1, T2, T3), or Prior to the layup step (b), the at least one fiber preform (T1, T2, T3) is pre-impregnated with the resin.

12. The manufacturing method according to any one of claims 9 to 11, characterized in that, In step (b), the metal insert (310) and the tool (O) are aligned axially side-by-side along the axis (A), and then the first fold of the composite material is at least partially laid over the inner surface (310c, O) of the metal insert (310). i On one of the radial surfaces (310a, 310b), a first fiber blank (T1) with an axial cross-section of L is formed.

13. The manufacturing method according to any one of claims 9 to 11, characterized in that, Step (b) includes the following sub-steps: (b1) The second fold of the composite material is laid at least partially on the inner surface (310c) and the radial surface (310a, 310b) of the metal insert (310) to form a second fiber blank (T2) with a U-shaped axial cross section. (b2) The third fold of the composite material is at least partially laid over the inner surface (O) of the tool (O). i ) and the radial surface (O r On the surface, a third fiber preform (T3) with an L-shaped axial cross-section is formed. (b3) The second fiber preform and the third fiber preform (T2, T3) respectively laid on the metal insert (310) and the tool (O) are aligned side by side along the axis (A), and (b4) The first fold of the composite material is at least partially laid on the annular inner surface (T2) of the second fiber preform and the third fiber preform (T2, T3). i T3 i ) and the annular radial surface (T2) of the second fiber preform (T2) r On the surface, a first fiber blank (T1) with an axial cross-section of L is formed.

14. The manufacturing method according to any one of claims 9 to 13, characterized in that, Prior to step (b), the method includes step (i): depositing an interface layer (308) at least partially on at least one of the inner surface (310c) and the radial surface (310a, 310b) of the metal insert (310).

15. The manufacturing method according to any one of claims 9 to 14, characterized in that, The resin is a thermosetting or thermoplastic material, such as epoxy resin, polyepoxide, polyimide, polybismaleimide, polyurethane, polyester, or vinyl ester.

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