COMPOSITE BLADE WITH INTEGRATED SHIELD AND MANUFACTURING PROCESS
The integration of a metallic soul within the composite material dawn addresses the sensitivity to impacts and manufacturing complexities of existing composite blades, resulting in improved stiffness, aerodynamics, and reduced lifecycle costs.
Patent Information
- Application Number
- FR2021012980
- Authority / Receiving Office
- FR · FR
- Patent Type
- Patents
- Current Assignee / Owner
- Filing Date
- 2021-12-06
- Publication Date
- 2025-03-28
- Estimated Expiration
- 2041-12-06
AI Technical Summary
Existing composite blades for blower and propeller applications are sensitive to punctual impacts, leading to damage such as delamination, and require complex and costly manufacturing and assembly processes for shields, which can result in non-conformities and increased lifecycle costs.
A composite material dawn with a polymer matrix reinforced by continuous carbon fibers, incorporating a metallic soul integrated within the composite body, which provides structural stiffness and protection while simplifying the manufacturing and assembly processes by being fully covered by continuous woven carbon fibers.
The solution reduces non-conformities and manufacturing costs, enhances the aerodynamic performance by maintaining the complex geometry of the blades, and improves impact resistance, thus extending the lifespan and reliability of the composite blades.
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Abstract
Description
Title of the invention: COMPOSITE BLADE WITH INTEGRATED SHIELD AND METHOD OF MANUFACTURING Technical field
[0001] The present disclosure relates to a blade made of composite material, such as a rotating blade or a guide blade. Prior art
[0002] In this context, the term "blades" refers to both fan blades and propeller blades. In order to limit their weight, these blades are typically made of a fiber-reinforced polymer matrix composite. Although these materials generally have very favorable mechanical qualities, particularly in relation to their mass, they are particularly sensitive to point impacts, which can generate, in particular, delamination phenomena within the material. Shields, typically made of a highly resistant metallic material, such as titanium alloys, are therefore normally installed on the leading edges of such blades, in order to protect them against these impacts. These shields normally take the form of a thin intrados fin and a thin extrados fin joined by a thicker section overlapping the leading edge, the assembly matching the shape of the blade on the leading edge and of the adjacent sections of the intrados and extrados.The intrados and extrados fins extend over these sections of, respectively, the intrados and extrados of the blade, and serve mainly to ensure the positioning and fixing of the shield on the leading edge.
[0003] In order to improve the aerodynamic performance of the blades, their leading edges have increasingly complex shapes, which complicates the manufacture of the shields that must match these shapes as well as the securing of the shield to the blade. The steps of manufacturing the leading edge and / or assembling the shield to the leading edge of the blade can lead to
[0004] Furthermore, during impacts on a blade, the shield may become at least partially detached from the leading edge of the composite blade and cause a deterioration in aerodynamic performance linked to the degradation of the aerodynamics of the blade accompanied by an imbalance in the case of a partial loss of the shield. In addition, if a portion of the shield is torn off, the leading edge of the blade is no longer protected over its entire height, the composite at the leading edge of the blade exposed is subjected to attacks from the external environment. The resulting profile is generally irregular which also leads to a loss of aerodynamics. The blade must then be repaired and / or replaced.
[0005] However, the leading edge shield may have numerous non-conformities. As non-limiting examples of non-conformities, the leading edge shield may have a cavity that is too wide or too narrow and / or undulations or grooves at the fins.
[0006] Similarly, after assembly of the leading edge shield on the blade body, the assembly may have numerous non-conformities. Indeed, even when the metal leading edge shield is compliant, it sometimes happens that the assembly by gluing of the leading edge shield on the blade body is ultimately non-compliant without the non-conformity(ies) being due to the blade body.
[0007] It may also be difficult to match a blade body to a leading edge shield. Non-destructive testing of the bonding assembly of the leading edge shield to the blade body is complex and repairing a damaged leading edge shield remains relatively complex and expensive.
[0008] The leading edge shield as it currently exists therefore induces many non-conformities and costs throughout its life cycle. Indeed, from the manufacture of the leading edge shield (high material price, many transformation operations, many scrap) through its assembly by gluing (essential surface preparation, long autoclave cycle, limited number of parts in the autoclave) to its repairability (biasing), the non-conformities are numerous and cause costs that could be reduced.
[0009] The problem posed is therefore not only the difficulty of producing enough compliant parts but also of reducing the cost of the parts and ensuring the robustness of the range. Statement of the invention
[0010] The present disclosure aims to remedy at least in part these drawbacks.
[0011] The present disclosure relates to a blade made of a polymer matrix composite material. reinforced with continuous carbon fibers, the blade comprising a blade body comprising woven continuous carbon fibers, the blade body comprising a leading edge and a trailing edge and a metal core disposed near the leading edge over a total height of the blade body, the metal core being completely covered by the woven continuous carbon fibers.
[0012] Thanks to the metal core, it is possible to obtain a blade made of composite material which has satisfactory stiffness as well as a complex geometry while reducing the non-conformities linked to the manufacture of the metal core and / or to the assembly of the metal core and the blade body. Furthermore, the metal core is easier to manufacture than a leading edge shield which has fins. Furthermore, since the metal core is included in the blade body, the assembly between the metal core and the blade body is facilitated.
[0013] By way of non-limiting examples, the metal core may be made of a metal alloy having no chemical interaction with the carbon fibers, for example, steel or titanium-based alloy.
[0014] In certain embodiments, the blade body comprises a blade tip and a blade root and the blade body comprises on the surface strands of fiberglass and / or kevlar® woven with the continuous carbon fibers, the strands of fiberglass and / or kevlar® extending from the leading edge over a chord length less than or equal to 50% and over a portion of the height of the blade body.
[0015] The glass and / or Kevlar® fibers on the surface provide better impact resistance.
[0016] In some embodiments, the blade body comprises a blade tip and a blade root and the blade body comprises on the surface strands of fiberglass and / or kevlar® woven with the continuous carbon fibers, the strands of fiberglass and / or kevlar® extending from the leading edge to the trailing edge over a portion of the height of the blade body.
[0017] In certain embodiments, the fiberglass and / or Kevlar® strands are arranged at the blade head over a height less than or equal to 45% of the total height of the blade body, preferably less than or equal to 30%, even more preferably less than or equal to 25%, even more preferably less than or equal to 15%.
[0018] In certain embodiments, the fiberglass and / or Kevlar® strands are arranged at the blade root over a height less than or equal to 45% of the total height of the blade body, preferably less than or equal to 30%, even more preferably less than or equal to 25%, even more preferably less than or equal to 15%.
[0019] In some embodiments, the metal core has, in sectional view, a rounded nose, a first face and a second face extending the rounded nose and a third flat face connecting the first face and the second face, the continuous woven carbon fibers having, in sectional view, a constant thickness on the first face and / or the second face and a thickness on the rounded nose, the thickness on the rounded nose being greater than or equal to the thickness on the first face and the thickness on the second face.
[0020] In some embodiments, the metal core has, in sectional view, a rounded nose, a first face and a second face extending the rounded nose and a third flat face connecting the first face and the second face, the continuous woven carbon fibers having, in sectional view, a variable thickness on the first face and / or the second face and a thickness on the rounded nose, the thickness on the rounded nose being greater than or equal to the thickness on the first face and the thickness on the second face.
[0021] In some embodiments, the continuous woven carbon fibers have a constant thickness over a total height of the first face and / or the second face and a constant thickness on the rounded nose, the thickness on the rounded nose being greater than or equal to the thickness on the first face and the thickness on the second face.
[0022] In some embodiments, the continuous woven carbon fibers have a variable thickness over a total height of the first face and / or the second face and a constant thickness on the rounded nose, the thickness on the rounded nose being greater than or equal to the thickness on the first face and the thickness on the second face.
[0023] The present disclosure also relates to a method for manufacturing a blade made of a composite material with a polymer matrix reinforced by continuous fibers as defined above, comprising the steps: manufacturing of the metal core; surface treatment of the metal core three-dimensional weaving of continuous carbon fibers, to form a draft of dawn body; cutting of weft and warp threads; shaping the blade body blank to form a blade body preform in a forming mold; insertion of the metal core into the blade body preform; drying and compacting of the blade body preform; injecting a polymer into the blade body preform in an injection mold; polymerization of the polymer.
[0024] In some embodiments, the three-dimensional weaving comprises on the surface the three-dimensional weaving of continuous carbon fibers and glass and / or Kevlar® fibers. Brief description of the drawings
[0025] Other characteristics and advantages of the subject of the present disclosure will emerge from the following description of embodiments, given as non-limiting examples, with reference to the appended figures.
[0026] [Fig-1] [Fig.l] is a schematic perspective view of a turbojet engine with double flow.
[0027] [Fig.2] [Fig.2] is a schematic perspective view of a rotating blade.
[0028] [Fig.3] [Fig.3] is a schematic perspective view of a fixed blade.
[0029] [Fig.4] [Fig.4] is a sectional view in plane IV-IV of [Fig.2].
[0030] [Fig.5] [Fig.5] is a sectional view in the plane VV of [Fig.3].
[0031] [Fig.6] [Fig.6] is a partial view of [Fig.4] according to a first mode of realization lization.
[0032] [Fig.7] [Fig.7] is a partial view of [Fig.4] according to a second embodiment.
[0033] [Fig.8] [Fig.8] is a flowchart representing the steps in a blade manufacturing process.
[0034] Throughout the figures, the elements in common are identified by identical numerical references. Detailed description
[0035] [Fig.l] illustrates a dual-flow turbojet 10 comprising a gas generator unit 12 and a fan 14. This fan 14 comprises a plurality of rotating blades 16, arranged radially around a central axis X, and aerodynamically profiled so as to impel the air by their rotation.
[0036] [Fig.2] illustrates a rotating blade 16, for example one of the rotating blades of the blower 14.
[0037] The rotating blade 16 is a blade made of a polymer matrix composite material reinforced with continuous fibers. The rotating blade 16 comprises a blade body 18 comprising continuous carbon fibers. The blade body 18 comprises a leading edge 20, a trailing edge 22, a blade tip 24 and a blade root 26.
[0038] As shown in [Fig.2], near the leading edge 20 of the blade body 18, a metal core 28 (shown in dotted lines) is arranged in the blade body 18. The metal core 28 is present over a total height H of the blade body 18.
[0039] In [Fig.2], the rotating blade 16 comprises on the surface strands 30 of glass fiber and / or kevlar® woven with the continuous carbon fibers of the blade body 18.
[0040] In the embodiment of [Fig. 2], the strands 30 of fiberglass and / or kevlar® extend from the leading edge 20 over a chord length less than or equal to 50% and over a portion of the height H of the blade body 18. In particular, in the embodiment of [Fig. 2], the strands 30 of fiberglass and / or kevlar® extend from the leading edge 20 over a chord length equal to 30% and at the blade tip over 25% of the height H of the blade body 18 measured from the blade tip 24.
[0041] In the following, the elements common to the different embodiments are identified by the same numerical references.
[0042] [Fig. 3] illustrates a fixed vane 32, also called a rectifier or OGV in accordance with the acronym in English for “Outlet Guide Vane”.
[0043] The fixed blade 32 is a blade made of a composite material with a reinforced polymer matrix. by continuous fibers. The fixed blade 32 comprises a blade body 18 comprising continuous carbon fibers. The blade body 18 comprises a leading edge 20, a trailing edge 22, a blade tip 24 and a blade root 26.
[0044] As shown in [Fig. 3], near the leading edge 20 of the blade body 18, a metal core 28 (shown in dotted lines) is arranged in the blade body 18. The metal core 28 is present over a total height H of the blade body 18.
[0045] In [Fig. 3], the fixed blade 32 comprises on the surface strands 30 of fiberglass and / or kevlar® woven with the continuous carbon fibers of the blade body 18.
[0046] In the embodiment of [Fig. 3], the strands 30 of fiberglass and / or kevlar® extend from the leading edge 20 to the trailing edge 22 and over a portion of the height H of the blade body 18. In particular, in the embodiment of [Fig. 3], the strands 30 of fiberglass and / or kevlar® extend from the leading edge 20 to the trailing edge 22 and at the blade tip 24 over 25% of the height H of the blade body 18 measured from the blade tip 24 and at the blade root 26 over 45% of the height H of the blade body 18 measured from the blade root 26.
[0047] Figures 4 and 5 respectively represent a sectional view along section plane IV-IV of [Fig.2] and a sectional view along section plane VV of [Fig.3]. In these sectional views, it can be seen that the metal core 28 is completely covered by the continuous carbon fibers of the blade body 18.
[0048] Figures 6 and 7 are partial views of [Fig.5], taken near the leading edge 20 and showing two embodiments.
[0049] In the embodiment of [Fig.6], the metal core 28 has in sectional view a rounded nose 28-1, a first face 28-2 and a second face 28-3 extending the rounded nose 28-1 and a third flat face 28-4 connecting the first face 28-2 and the second face 28-3. The metal core 28 has a length La measured between the rounded nose 28-1 of the metal core 28 and the third flat face 28-4 and a length Lb of the third flat face 28-4. The continuous woven carbon fibers have, in sectional view, a constant thickness t2 on the first face 28-2 and a constant thickness t3 on the second face 28-3 and a thickness tl on the rounded nose, the thickness tl on the rounded nose being greater than or equal to the thickness t2 on the first face 28-2 and the thickness t3 on the second face 28-3.
[0050] As a non-limiting example, in the embodiment of [Fig. 6], the thickness tl on the rounded nose is equal to four layers of continuous carbon fibers and the thicknesses t2 and t3 are equal to two layers of continuous carbon fibers. It will be noted that the length Lnez corresponds to the sum of the length La of the metal core and the thickness tl of the rounded nose 28-1 and that the thickness Emax of the blade body 18 measured at the length Lnez is equal to the sum of the length Lb of the third flat face 28-4 and the thicknesses t2 on the first face 28-2 and t3 on the second side 28-3.
[0051] In the embodiment of [Fig.7], the metal core 28 has in sectional view a rounded nose 28-1, a first face 28-2 and a second face 28-3 extending the rounded nose 28-1 and a third flat face 28-4 connecting the first face 28-2 and the second face 28-3. The metal core 28 has a length La measured between the rounded nose 28-1 of the metal core 28 and the third flat face 28-4 and a length Le of the third flat face 28-4. The continuous woven carbon fibers have, in sectional view, a variable thickness ranging from t2 to t4 on the first face 28-2 and a variable thickness ranging from t3 to t5 on the second face 28-3 and a thickness tl on the rounded nose, the thickness tl on the rounded nose being greater than or equal to the thicknesses t2 and t4 on the first face 28-2 and to the thicknesses t3 and t5 on the second face 28-3. The thicknesses t4 and t5 are measured at the third flat face 28-3.
[0052] As a non-limiting example, in the embodiment of [Fig. 7], the thickness tl on the rounded nose is equal to four layers of continuous carbon fibers and the thicknesses t4 and t5 are equal to two layers of continuous carbon fibers. The thickness t2 may be between the thickness tl on the rounded nose and the thickness t4. The thickness t3 may be between the thickness tl on the rounded nose and the thickness t5. It will be noted that the length Lnose corresponds to the sum of the length La of the metal core and the thickness tl of the rounded nose 28-1 and that the thickness Emax of the blade body 18 measured at the length Lnose is equal to the sum of the length Le of the third flat face 28-4 and the thicknesses t4 on the first face 28-2 and t5 on the second face 28-3.
[0053] Alternatively, the thickness of the woven continuous carbon fibers may be constant on the first face 28-2 and variable on the second face 28-3. Conversely, the thickness of the woven continuous carbon fibers may be variable on the first face 28-2 and constant on the second face 28-3.
[0054] It is understood that the thicknesses t1-t5 can be constant along the height H of the blade body 18 or vary independently of each other along the height H of the blade body 18. Thus, certain thicknesses can be constant and others can be variable.
[0055] [Fig.8] is a flowchart representing the steps of a manufacturing method 100 of a rotating blade 16 or a fixed blade 32.
[0056] The manufacturing method 100 comprises a first step 102 of manufacturing the metal core 28, for example by forging, machining or cutting from the mass or possibly by electrodeposition.
[0057] The metal core 28 then undergoes a surface treatment 104 of the metal core 28 in order to ensure good adhesion of the polymer matrix.
[0058] The manufacturing method 100 comprises a step of three-dimensional weaving 106 of continuous carbon fibers, to form a blade body blank.
[0059] Once the blank is obtained, the blank undergoes a step 108 of cutting weft and warp threads.
[0060] The blank is then shaped 110 in a forming mold to form a blade body preform.
[0061] The metal core 28 is inserted into the blade body preform (step 112).
[0062] The blade body preform into which the metal core has been inserted undergoes a drying and compacting step 114 of the blade body preform, for example in an autoclave / oven.
[0063] The compacted blade body preform is placed in an injection mold and a polymer is then injected into the compacted preform (step 116). As a non-limiting example, the injection can be carried out by a resin transfer molding process, also called RTM according to the acronym in English for “Resin Transfer Molding”.
[0064] The polymer is then polymerized (step 118) to obtain a blade 16, 32.
[0065] During the three-dimensional weaving step 106, strands 30 of fiberglass and / or kevlar® can be woven with the continuous carbon fibers to form a surface reinforcement against impact.
[0066] Although the present disclosure has been described with reference to a specific exemplary embodiment, it is obvious that various modifications and changes may be made to these examples without departing from the general scope of the invention as defined by the claims. Furthermore, individual features of the various embodiments recited may be combined in additional embodiments. Therefore, the description and drawings should be considered in an illustrative rather than restrictive sense.
Claims
Claims
1. A blade (16, 32) made of a polymer matrix composite material reinforced with continuous carbon fibers, the blade comprising a blade body (18) comprising woven continuous carbon fibers, the blade body comprising a leading edge (20) and a trailing edge (22) and a metal core (28) disposed near the leading edge (20) over a total height (H) of the blade body, the metal core (28) being completely covered by the woven continuous carbon fibers.
2. A blade (16, 32) according to claim 1, wherein the blade body (18) comprises a blade head (24) and a blade root (26) and the blade body comprises on the surface strands (30) of fiberglass and / or kevlar® woven with the continuous carbon fibers, the strands (30) of fiberglass and / or kevlar® extending from the leading edge (20) over a chord length less than or equal to 50% and over a portion of the height (H) of the blade body.
3. A blade (16, 32) according to claim 1, wherein the blade body comprises a blade tip (24) and a blade root (26) and the blade body comprises on the surface strands (30) of fiberglass and / or kevlar® woven with the continuous carbon fibers, the strands (30) of fiberglass and / or kevlar® extending from the leading edge (20) to the trailing edge (20) over a portion of the height (H) of the blade body.
4. Blade (16, 32) according to claim 2 or 3, in which the strands (30) of fiberglass and / or kevlar® are arranged at the blade head (24) over a height less than or equal to 45% of the total height of the blade body, preferably less than or equal to 30%, even more preferably less than or equal to 25%.
5. Blade (16, 32) according to any one of claims 3 or 4, in which the strands (30) of fiberglass and / or kevlar® are arranged at the base of the blade (26) over a height less than or equal to 45% of the total height of the blade body, preferably less than or equal to 30%, even more preferably less than or equal to 25%.
6. A blade (16, 32) according to any one of claims 1 to 5, wherein the metal core (28) has, in sectional view, a rounded nose (28-1), a first face (28-2) and a second face (28-3) extending the rounded nose and a third flat face (28-4) connecting the first face and the second face, the continuous woven carbon fibers having, in sectional view, a constant thickness on the first face (28-1) and / or the second face (28-3) and a thickness on the rounded nose (28-1), the thickness on the rounded nose being greater than or equal to the thickness on the first face and the thickness on the second face.
7. A blade (16, 32) according to any one of claims 1 to 5, wherein the metal core (28) has, in sectional view, a rounded nose (28-1), a first face (28-2) and a second face (28-3) extending the rounded nose and a third flat face (28-4) connecting the first face and the second face, the continuous woven carbon fibers having, in sectional view, a variable thickness on the first face (28-2) and / or the second face (28-3) and a thickness on the rounded nose (28-1), the thickness on the rounded nose being greater than or equal to the thickness on the first face and the thickness on the second face.
8. A blade (16, 32) according to claim 6 or 7, wherein the continuous woven carbon fibers have a constant thickness over a total height of the first face and / or the second face and a constant thickness on the rounded nose, the thickness on the rounded nose being greater than or equal to the thickness on the first face and the thickness on the second face.
9. A blade (16, 32) according to claim 6 or 7, wherein the continuous woven carbon fibers have a variable thickness over a total height of the first face and / or the second face and a constant thickness on the rounded nose, the thickness on the rounded nose being greater than or equal to the thickness on the first face and the thickness on the second face.