Carbon fiber composite casing stator

Abstract

The composite material casing stator comprises a motor base and a plurality of blades connected in the circumferential direction of the motor base, the motor base is formed by machining aluminum alloy, and each blade comprises a composite material blade body and metal connecting pieces arranged at the two ends of the composite material blade body; the composite material blade body comprises a foam sandwich and a carbon fiber composite material skin wrapping the foam sandwich, the overall weight of a casing stator can be greatly reduced through the design, and the overall strength of the blade is improved; the metal connecting piece is locally embedded in the composite material blade body to be integrally formed, then connection is reinforced through the rivets, the structural strength is high, the precision is guaranteed, all the rivets or bolt pier heads on the blade do not protrude out, and the aerodynamic shape of a casing stator is stable.

Description

Technical Field

[0001] The present invention relates to the field of composite materials, and in particular to a carbon fiber composite material casing stator. Background Art

[0002] With technological advancements and people's pursuit of a faster, more convenient lifestyle, the concept of personal flying vehicles (PFDs) has become increasingly popular. To meet their lightweight and agile requirements, these vehicles require higher engine power and overall weight. To increase the engine's bypass ratio and efficiency, larger blades are required, which increases the proportion of the blades to the total engine weight. Reducing the weight of blade segments is a key approach to reducing engine weight and improving efficiency. According to relevant data, for every 1kg reduction in blade weight, the casing and transmission system also reduce 1kg. This effect of blade weight reduction is crucial to the overall weight reduction of the aircraft.

[0003] Compared with metal materials, carbon fiber composites have the following obvious advantages: the density of carbon fiber composites is only 1.65g / cm 3 , which is higher than the density of titanium alloy (4.51g / cm 3 ) is even lower, making it the preferred material for lightweighting. Furthermore, metal materials are isotropic in strength, and increasing strength can only be achieved by thickening them, which results in performance loss in certain directions. Single-layer carbon fiber, on the other hand, has distinct directionality, and the mechanical properties of a single-layer plate along the fiber direction are 1 to 2 orders of magnitude higher than those in the direction perpendicular to the fiber and in the longitudinal and transverse shear properties. Therefore, targeted designs can be tailored to the load distribution characteristics to achieve the required stiffness and strength. Furthermore, carbon fiber composites are superior to metal materials in terms of vibration resistance, especially anti-flutter.

[0004] However, since the motor base can usually only be made of metal, the carbon fiber composite blades need to be formed separately and then assembled with the motor base. For the case stator with high aerodynamic requirements, if the conventional method of drilling bolt holes in the blades and then connecting them to the motor base with bolts is used, the stability of the case stator will be affected. If adhesive bonding is used, the connection strength may be insufficient. Therefore, the connection of carbon fiber composite blades to the motor base and other components is a technical problem faced in the production of carbon fiber composite case stators. Summary of the Invention

[0005] The utility model aims to provide a composite material casing stator, which solves the problem of good connection between the blades and the motor seat and realizes the lightweight of the casing stator on the basis of meeting the rigidity and strength of the blades.

[0006] The technical solution of this application is as follows:

[0007] A carbon fiber composite casing stator comprises a motor base and several blades arranged circumferentially around the motor base. The motor base is machined from aluminum alloy, and the blades comprise a composite blade body and metal connectors at both ends of the composite blade body. In this solution, the use of a metal motor base and composite blades significantly reduces the weight of the casing stator, while also emphasizing the high strength of the composite material.

[0008] In another embodiment, the composite blade body includes a foam core and a skin covering the foam core; the metal connector includes an inner end metal connector for connecting to a motor base, and an outer end metal connector away from the motor base.

[0009] In another embodiment, the inner end metal connector includes a first connecting end embedded in the composite blade body and a first mounting end face that cooperates with the motor seat; the outer end metal connector includes a second connecting end embedded in the composite blade body and a second mounting end face that is connected to other counterparts.

[0010] In another embodiment, the first connecting end of the inner metal connector and the second connecting end of the outer metal connector are respectively connected to the ends of the foam core; the skin completely covers the foam core and the first and second connecting ends. By partially embedding the metal connector into the composite blade body, the metal connector and the blade body maintain good connection strength after co-curing.

[0011] In another embodiment, slots are provided on the upper and lower sides of the first and second connecting ends, and overlapping ends are provided at both ends of the foam core to accommodate the slots. The overlapping ends of the foam core are positioned within the slots, and the first and second connecting ends are bonded to the foam core using structural adhesive. The metal connector slots mate with the overlapping ends of the foam core, and the structural adhesive is used to bond the metal connector to the composite blade body to ensure strength.

[0012] In another embodiment, the skin includes, from the inside out, a carbon fiber unidirectional tape layer and a carbon fiber fabric layer; the carbon fiber unidirectional tape can be selected from T700 carbon fiber unidirectional tape, T800 carbon fiber unidirectional tape, etc.; the carbon fiber fabric can be selected from T300 or higher carbon fiber twill fabric. The axial direction of the composite blade is defined as 0°, and the ply angle of the carbon fiber unidirectional tape is 0° / 90°. The number of carbon fiber unidirectional tape layers in the 0° direction accounts for 70% of the total number of carbon fiber unidirectional tape layers, mainly playing a load-bearing role. The number of carbon fiber unidirectional tape layers in the 90° direction accounts for 30% of the total number of carbon fiber unidirectional tape layers. The carbon fiber unidirectional tape in the 90° direction is laid around the carbon fiber unidirectional tape in the 0° direction to prevent the 0° carbon fiber unidirectional tape from being dispersed.

[0013] In another embodiment, a glass fiber fabric layer is further provided between the first connection end of the inner metal connector and the carbon fiber unidirectional tape layer, and between the second connection end of the outer metal connector and the carbon fiber unidirectional tape layer. The glass fiber fabric is specifically, for example, EW100 glass fiber fabric.

[0014] In another embodiment, the motor base is provided with a groove adapted to mate with the first mounting end surface; the first mounting end surface is mounted and fixed in the groove. Providing a groove adapted to the first mounting end surface facilitates locking the relative position of the blade and the motor base, reducing assembly costs, while also ensuring that the overall streamlined appearance of the product is not compromised.

[0015] In another embodiment, the groove is provided with a screw hole, and the first mounting end surface is also provided with a countersunk hole corresponding to the screw hole, which is used to securely connect the blade to the motor base with a bolt. By providing the screw hole on the first mounting end surface as a countersunk hole, the bolt head does not protrude, thereby ensuring the stability of the aerodynamic shape.

[0016] In another embodiment, the first connecting end, the second connecting end and the composite blade body are further connected to each other with rivets to strengthen the connection strength.

[0017] In another embodiment, a foaming rubber layer is provided between the foam core and the skin. During molding, the foaming rubber expands due to heat, providing pressure from the inside out to the blade, thereby ensuring the appearance quality of the composite blade.

[0018] Compared with the existing technology, the advantages are as follows: (1) The blade is mainly composed of a foam core and a carbon fiber composite skin, which greatly reduces the overall weight of the casing stator; (2) The skin is made of carbon fiber unidirectional tape prepreg and carbon fiber fabric prepreg, which improves the overall strength of the blade; (3) The metal connectors are embedded in the composite blade body and formed as a whole, and then the connection is strengthened by rivets, which has high structural strength and guaranteed precision; (4) The blade bolt / rivet head does not protrude and does not affect the aerodynamic shape of the casing stator. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 Schematic diagram of the casing stator structure;

[0020] Figure 2 This is a schematic diagram of the motor base structure;

[0021] Figure 3 Schematic diagram of the blade structure;

[0022] Figure 4 This is a schematic diagram of the explosion of the inner metal connector and the blade;

[0023] Figure 5 Schematic diagram of the structure of the outer metal connector;

[0024] Figure 6 It is a schematic diagram of the AA section;

[0025] Among them: 1-motor base; 11-groove; 2-blade; 21-blade body; 211-foam core; 212-skin; 22-inner end metal connector; 221-first connection end; 222-first mounting end face; 23-outer end metal connector; 231-second connection end; 232-second mounting end face; 3-screw hole; 4-countersunk screw hole; 5-slot. DETAILED DESCRIPTION

[0026] In order to enable those skilled in the art to better understand the present invention, the following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts should fall within the scope of protection of this application.

[0027] It should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicating positions or locations, are based on the positions or locations shown in the accompanying drawings and are intended solely to facilitate and simplify the description of the present invention. They are not intended to indicate or imply that the devices or components referred to must have a specific orientation, be constructed, or operate in a specific orientation. Therefore, they should not be construed as limitations on the present invention. Furthermore, the terms "first" and "second," etc., are used to distinguish similar objects, rather than to describe a specific order or precedence.

[0028] In the description of this utility model, it should be noted that, unless otherwise explicitly stated or limited, the terms "installed," "connected," and "connected" are to be understood broadly. For example, they may refer to fixed or detachable connections, mechanical or electrical connections, and direct or through an intermediary. Those skilled in the art will understand the specific meanings of these terms in this utility model based on the specific circumstances.

[0029] like Figure 1 As shown, a carbon fiber composite casing stator includes a motor base 1 and a plurality of blades 2 arranged circumferentially on the motor base 1; the motor base 1 is machined from aluminum alloy, and the blades 2 include a composite blade body 21 and metal connectors arranged at both ends of the composite blade body 21.

[0030] The composite blade body 21 includes a foam core 211 and a skin 212 covering the foam core 211 ; the metal connector includes an inner metal connector 22 for connecting to the motor base 1 , and an outer metal connector 23 away from the motor base 1 .

[0031] The inner end metal connector 22 includes a first connecting end 221 embedded in the composite blade body and a first mounting end face 222 that cooperates with the motor base 1; the outer end metal connector 23 includes a second connecting end 231 embedded in the composite blade body and a second mounting end face 232 for connecting to other counterparts.

[0032] The first connecting end 221 of the inner metal connector 22 and the second connecting end 231 of the outer metal connector 23 are respectively connected to the ends of the foam core 211. The skin 212 completely covers the foam core 211 and the first and second connecting ends 221 and 231. By partially embedding the metal connectors within the composite blade body 21, the metal connectors maintain a good connection strength with the composite blade body 21.

[0033] The first connecting end 221 of the inner metal connector 22 and the second connecting end 231 of the outer metal connector 23 are both provided with slots 5 on their upper and lower sides. The foam core 211 is provided with overlapping ends at both ends that fit within the slots 5. A structural adhesive layer is also applied to the areas where the first and second connecting ends 221, 231 connect to the foam core 211 for bonding. This increases the connection area between the metal connector and the composite blade body 21, enhancing the connection strength.

[0034] The connection parts between the composite blade body 21 and the first connection end 221 and the second connection end 231 are further provided with a plurality of countersunk screw holes 4 for strengthening the connection between the composite blade body 21 and the metal connector by rivets.

[0035] The skin 212 comprises, from the inside out, layers of carbon fiber unidirectional tape and carbon fiber fabric. The carbon fiber unidirectional tape is T700 carbon fiber unidirectional tape, and the carbon fiber fabric is T300 carbon fiber twill fabric. The T700 carbon fiber unidirectional tape is laid at a 0° / 90° angle, with the ratio of the 0° to 90° carbon fiber unidirectional tape layers being 7:3. By wrapping around the 0° carbon fiber unidirectional tape, the 0° carbon fiber unidirectional tape is prevented from dispersing.

[0036] EW100 glass fiber fabric is also provided between the first connecting end of the inner end metal connector and the carbon fiber unidirectional tape, and between the second connecting end of the outer end metal connector and the carbon fiber unidirectional tape, to prevent potential corrosion of the product during subsequent long-term use.

[0037] The motor base is provided with a groove that matches the first mounting end surface, and the first mounting end surface can be fitted into the groove. The groove is provided with a screw hole, and the first mounting end surface is also provided with a countersunk screw hole 4 corresponding to the screw hole, which is used to connect the blade to the motor base with a bolt.

[0038] A countersunk screw hole 4 is also provided on the second mounting end surface of the outer metal connector.

[0039] A foaming rubber layer is provided between the foam core and the skin. During molding, the foaming rubber expands due to heat, providing pressure from the inside out to the blade, thereby ensuring the appearance quality of the composite material blade.

Claims

1. A carbon fiber composite casing stator, comprising a motor base and a plurality of blades connected to the motor base in the circumferential direction, wherein the motor base is machined from aluminum alloy, and is characterized in that: The blade includes a composite blade body and metal connectors arranged at both ends of the composite blade body; the composite blade body includes a foam core and a skin covering the foam core; the metal connector includes an inner end metal connector for connecting to a motor base, and an outer end metal connector away from the motor base.

2. The carbon fiber composite material casing stator according to claim 1, characterized in that: The inner end metal connector includes a first connecting end embedded in the composite blade body and a first mounting end face that cooperates with the motor seat; the outer end metal connector includes a second connecting end embedded in the composite blade body and a second mounting end face that is connected to other counterparts.

3. The carbon fiber composite casing stator according to claim 2, characterized in that: The first connecting end and the second connecting end are respectively connected to two ends of the foam core; the skin completely covers the foam core and the first connecting end and the second connecting end.

4. The carbon fiber composite material casing stator according to claim 3, characterized in that: The upper and lower sides of the first connecting end and the second connecting end are provided with card slots, and the two ends of the foam core are provided with overlapping ends adapted to the card slots; the overlapping ends of the foam core are arranged in the card slots; the first connecting end, the second connecting end and the foam core connection area are also bonded with structural adhesive.

5. The carbon fiber composite casing stator according to claim 2, characterized in that: The skin includes a carbon fiber unidirectional tape layer and a carbon fiber fabric layer from the inside to the outside; the axial direction of the composite material blade is defined as 0°, and the ply ratio of the carbon fiber unidirectional tape layer is 0°:90°=7:

3.

6. The carbon fiber composite material casing stator according to claim 5, characterized in that: A glass fiber fabric layer is further provided between the first connecting end, the second connecting end and the carbon fiber unidirectional tape layer.

7. The carbon fiber composite casing stator according to claim 1, characterized in that: The motor seat is provided with a groove adapted to the first mounting end surface; the first mounting end surface is installed and fixed in the groove.

8. The carbon fiber composite material casing stator according to claim 7, characterized in that: The groove is provided with a screw hole, and the first mounting end surface is also provided with a countersunk hole corresponding to the screw hole, which is used to connect the blade to the motor base with a bolt.

9. The carbon fiber composite material casing stator according to claim 3, characterized in that: The first connecting end, the second connecting end and the composite blade body are further connected to each other with rivets to strengthen the connection strength.

10. The carbon fiber composite material casing stator according to claim 1, characterized in that: A foaming rubber layer is further provided between the foam core and the skin.

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