CA2043747C - Method of manufacturing fan blades - Google Patents
Method of manufacturing fan bladesInfo
- Publication number
- CA2043747C CA2043747C CA002043747A CA2043747A CA2043747C CA 2043747 C CA2043747 C CA 2043747C CA 002043747 A CA002043747 A CA 002043747A CA 2043747 A CA2043747 A CA 2043747A CA 2043747 C CA2043747 C CA 2043747C
- Authority
- CA
- Canada
- Prior art keywords
- preform
- set forth
- cloths
- fan blade
- resin
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
Links
- 238000004519 manufacturing process Methods 0.000 title claims description 8
- 239000011347 resin Substances 0.000 claims abstract description 38
- 229920005989 resin Polymers 0.000 claims abstract description 38
- 238000000034 method Methods 0.000 claims abstract description 20
- 239000003365 glass fiber Substances 0.000 claims description 15
- 239000011230 binding agent Substances 0.000 claims description 12
- 239000011888 foil Substances 0.000 claims description 10
- 238000010276 construction Methods 0.000 claims description 8
- 239000000463 material Substances 0.000 claims description 7
- 239000000835 fiber Substances 0.000 claims description 3
- 239000011521 glass Substances 0.000 claims description 2
- 239000011152 fibreglass Substances 0.000 abstract description 34
- 238000000465 moulding Methods 0.000 abstract description 6
- 239000004744 fabric Substances 0.000 abstract description 5
- 230000037303 wrinkles Effects 0.000 description 3
- 238000002347 injection Methods 0.000 description 2
- 239000007924 injection Substances 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 238000005452 bending Methods 0.000 description 1
- 230000007812 deficiency Effects 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
- 230000037431 insertion Effects 0.000 description 1
- 238000011835 investigation Methods 0.000 description 1
- 230000014759 maintenance of location Effects 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 230000000452 restraining effect Effects 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D99/00—Subject matter not provided for in other groups of this subclass
- B29D99/0025—Producing blades or the like, e.g. blades for turbines, propellers, or wings
- B29D99/0028—Producing blades or the like, e.g. blades for turbines, propellers, or wings hollow blades
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
- B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
- B29C70/443—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding and impregnating by vacuum or injection
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
- B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
- B29C70/446—Moulding structures having an axis of symmetry or at least one channel, e.g. tubular structures, frames
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
- B29C70/541—Positioning reinforcements in a mould, e.g. using clamping means for the reinforcement
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
- B29C43/36—Moulds for making articles of definite length, i.e. discrete articles
- B29C43/3642—Bags, bleeder sheets or cauls for isostatic pressing
- B29C2043/3649—Inflatable bladders using gas or fluid and related details
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
- B29C43/10—Isostatic pressing, i.e. using non-rigid pressure-exerting members against rigid parts or dies
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
- B29C43/10—Isostatic pressing, i.e. using non-rigid pressure-exerting members against rigid parts or dies
- B29C43/12—Isostatic pressing, i.e. using non-rigid pressure-exerting members against rigid parts or dies using bags surrounding the moulding material or using membranes contacting the moulding material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/08—Blades for rotors, stators, fans, turbines or the like, e.g. screw propellers
Abstract
A method and apparatus of molding a hollow fan blade is disclosed wherein a fiberglass preform is used to support the upper layers of fiberglass cloth within a mold. As resin is injected into the mold, both the fiberglass cloth and the fiberglass preform become impregnated thereby bonding the two together into a single unit during the molding operation during which heat and pressure is applied.
Description
204~747 METHOD FOR M~NUFACTURING FAN BLADES
FIELD OF THE INVENTION
This invention pertains to a method of manufacturing fiberglass fan blades and more particularly to the use of a fiberglass preform for manufacturing hollow, one-piece fan blades.
BACKGROUND OF THE INVENTION
The art of manufacturing fan blades is quite varied. The method used depends on whether the finished fan blade is to be hollow or solid, and whether it is to be one piece or of multiple pieces secured together. The method used also depends on the desired air-foil shape with simple shapes being suitable for pressing while more complex shapes require molding or laying-up techniques. This invention pertains to the construction of hollow, one-piece, fiberglass fan blades of a rather complex configuration such that resin transfer or injection molding is the method of choice. No internal spars or fillers are necessary to provide additional bending strength during operation. This hollow, light construction also produces a blade that is safer to operate as compared to blades with molded-in spars.
In the past, such hollow fan blades were made in two pieces, the first comprising the air foil shape while the second comprised the blade holder that attached the air foil to the rotating shaft or hub. In some cases (U.S. 4,345,877 to R.C.
Monroe) the air foil and the blade holder were made of different material. In other cases (U.S. 4,720,244 to Kluppel et al.) the 20~37~7 pieces were made of fiberglass that were then bonded or riveted together.
In the latter, all fiberglass case, the blade is formed by wrapping multiple fiberglass cloth layers around a flexible bag within a mold, inflating the bag, and then forcing resin into the mold so as to impregnate the fiberglass cloths. Afterwards, the fan blade is cured and the flexible bag is removed. In an attempt to more evenly distribute the resin (so as to avoid resin build-up or resin-rich areas which are likely to crack) and to avoid wrinkles in the fiberglass, "spreaders" or rigid forms were installed inside the flexible bag and expanded therein to further support the fiberglass cloths. This spreader was used inside both the fiberglass blade holder or attachment end as well as inside the air foil end during molding. The insertion and later removal of the spreaders before assembly of the blade and holder is labor intensive and limits the minimum size and shape of the neck portion of the fan blade. The spreader greatly increased the quality of the product but necessitated making a blade in two pieces since they had to be removed from the interior of the parts.
The typical method of making hollow, one-piece fan blades involves using crude cardboard shapes inside the pressurized flexible bags. This, of course, results in a fan blade of non-uniform wall thickness. Additionally, the cardboard shapes produce a fan blade that is full of wrinkles in the fiberglass layers and cracked resin-rich areas because of the shifting of the fiberglass cloth within the mold as resin is injected through the neck region. In most normal cases, the cardboard is unable to precisely hold and locate the fiberglass layers before resin injection.
It is thus an object of this invention to overcome these deficiencies and to provide a method of manufacturing a hollow, one-piece fan blade that is less labour intensive, is stronger, more aesthetically pleasing to the eye and results in fewer rejects than the methods previously used to construct such fan blades. Another object of this invention is to provide a method that specifically reduces the occurrence of resin-rich areas while also providing support and precise placement and retention of the fiberglass cloths so as to reduce their wrinkling or shifting when the resin is forced into the mold. These and other objects of this invention will become obvious upon further investigation.
SUMMARY OF THE INVENTION
According to one aspect of the present invention there is provided a method of manufacturing a hollow fan blade comprising the steps of laying glass fiber cloths within a lower portion of a mold; placing a flexible inflatable bag on said cloths within said mold; inserting a semi rigid preform conforming to the shape of one side of the blade on top of said flexible bag, said preform being temporarily held together by a suitable resin binder; covering said preform with said cloths or additional cloths; closing said mold and inflating said flexible bag;
injecting resin into said mold around said flexible bag thereby both impregnating said cloths and said preform and replacing said 20 ~37 47 -3a-resin binder in said preform thereby bonding said cloths and said preform together into a single unit; and curing the fan blade, deflating said flexible bag, and removing the fan blade from said mold.
According to a further aspect of the present invention there is provided a method of constructing hollow fan blades comprising the steps of supporting glass fiber material within a mold upon a temporary preform; and injecting said preform and said material with resin, said resin replacing the binder resin of said preform, thereby bonding said preform and said material together to form said fan blade.
According to a still further aspect of the present invention there is provided a molded, hollow fan blade constructed of upper and lower layers of resin-impregnated glass fan fiber cloths and having an internal cavity therein, wherein the improvement comprises a solitary, cured, glass fiber preform within the fan blade and defining a portion of the internal cavity therein, said preform configured to engage and solely support the upper layers of the cloths and comprising a unitary, stationary, curved, panel; and resin binding means for integrally bonding said preform solely to the upper layers of the cloths.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a pictorial view partially broken away of the finished fan blade.
2û43747 Fig. 2 is a pictorial view of the fiberglass preform.
Fig. 3 is a sectional view taken along lines 3-3 of Fig. 2.
Fig. 4 is a sectional view taken along lines 4-4 of Fig. 2.
Fig. 5 is a sectional view taken along lines 5-5 of Fig. 2.
Fig. 6 is a pictorial view of the lay-up operation.
Fig. 7 is a pictorial view of the mold enclosing the preform and flexible bag.
Fig. 8 is a pictorial view of the mold during the curing operation.
DETAILED DESCRIPTION OF THE INVENTION
Referring initially to Fig. 1, there is shown hollow fan blade 10 having a neck portion 12 and an air foil portion 14.
Neck portion 12 is configured with collar 16 for connecting with a rotating shaft or hub (not shown). Air foil portion 14 is configured as needed for the operating conditions, but in any event, its hollow construction is of multi-layered fiberglass.
No metallic internal spar is needed to supply adequate strength for safe operation.
Preform 18, as shown in Fig. 2, is used in the construction of fan blade 10, in fact, preform 18 is designed to eventually become a part of fan blade lO. The curvature of preform 18 can vary as needed with typical curvatures illustrated in Figs. 3, 4, and 5. As can be surmised, preform 18 is designed only to support the upper layers of fiberglass cloths in a mold until they are saturated with resin and cured. The lower layers of the fiberglass cloths will be supported by the bottom half of the mold. Consequently, the entire shape of fan blade 10 need not be supported by preform 18, only the upper half of it.
- 2043747.
Preform 18 is preferably constructed of chopped fiberglass fibers which have been shaped as needed by being blown or a fiberglass mat laid onto a mandril of the desired curvature.
After the required thickness has been achieved, the chopped fiberglass or mat is held together by impregnating it with a light resin binder with this mixture then being oven cured to create the desired semi-rigid preform 18. The light binder resin used to hold preform 18 together is compatible with the resin used during the molding of fan blade 10. After preform 18 is cured, it is stripped off its mandril and used to support the upper layers of the fiberglass cloths in a mold for constructing fan blade 10. Thus, preform 18 is constructed to conform to the finished blade shape for precise fiberglass placement.
Referring now to Figs. 6-8, the steps required to mold fan blade 10 are shown. Initially, the bottom half 20 of mold 22 is laid with varying layers of fiberglass cloths 24 or other fiberglass types. On top of this, flexible bag 26 is placed which will be pressurized once mold 22 is closed. While flexible bag 26 is still deflated, however, preform 18 is positioned on top of it so as to support the upper layers of fiberglass cloths 24 which will be folded around it and/or placed on top of it.
Because preform 18 is able to maintain and precisely position the dry laid-up fiberglass cloths 24 within mold 22, the possibility of wrinkles and/or resin-rich areas within mold 22 are greatly reduced, if not completely eliminated.
After mold 22 is closed and clamped, flexible bag 26 is inflated through neck portion 12 and subsequently sealed thereby also restraining dry fiberglass cloths 24 in place within mold _ -6-22. Upon proper inflation, resin is pumped or injected into mold 22 via neck portion 12 to saturate both preform 18 and the fiberglass cloth layers 24 thereby binding the two together.
Heat is then applied to cure this mixture afterwhich flexible bag 26 is removed after mold 22 is opened to release newly formed fan blade 10.
The use of preform 18 enables fiberglass cloths 24 to be maintained at their optimum position upon the closing of mold 22.
Additionally, preform 18 can be formed into any planform shape, straight or tapered, and can easily accommodate a tapered attachment end (neck portion 12) that normally terminates into a cylindrical clamping area for suitable mounting. With the disclosed resin transfer method or resin injection method of molding, a more aerodynamically efficient, stronger and aesthetically pleasing one-piece fan blade can be manufactured.
FIELD OF THE INVENTION
This invention pertains to a method of manufacturing fiberglass fan blades and more particularly to the use of a fiberglass preform for manufacturing hollow, one-piece fan blades.
BACKGROUND OF THE INVENTION
The art of manufacturing fan blades is quite varied. The method used depends on whether the finished fan blade is to be hollow or solid, and whether it is to be one piece or of multiple pieces secured together. The method used also depends on the desired air-foil shape with simple shapes being suitable for pressing while more complex shapes require molding or laying-up techniques. This invention pertains to the construction of hollow, one-piece, fiberglass fan blades of a rather complex configuration such that resin transfer or injection molding is the method of choice. No internal spars or fillers are necessary to provide additional bending strength during operation. This hollow, light construction also produces a blade that is safer to operate as compared to blades with molded-in spars.
In the past, such hollow fan blades were made in two pieces, the first comprising the air foil shape while the second comprised the blade holder that attached the air foil to the rotating shaft or hub. In some cases (U.S. 4,345,877 to R.C.
Monroe) the air foil and the blade holder were made of different material. In other cases (U.S. 4,720,244 to Kluppel et al.) the 20~37~7 pieces were made of fiberglass that were then bonded or riveted together.
In the latter, all fiberglass case, the blade is formed by wrapping multiple fiberglass cloth layers around a flexible bag within a mold, inflating the bag, and then forcing resin into the mold so as to impregnate the fiberglass cloths. Afterwards, the fan blade is cured and the flexible bag is removed. In an attempt to more evenly distribute the resin (so as to avoid resin build-up or resin-rich areas which are likely to crack) and to avoid wrinkles in the fiberglass, "spreaders" or rigid forms were installed inside the flexible bag and expanded therein to further support the fiberglass cloths. This spreader was used inside both the fiberglass blade holder or attachment end as well as inside the air foil end during molding. The insertion and later removal of the spreaders before assembly of the blade and holder is labor intensive and limits the minimum size and shape of the neck portion of the fan blade. The spreader greatly increased the quality of the product but necessitated making a blade in two pieces since they had to be removed from the interior of the parts.
The typical method of making hollow, one-piece fan blades involves using crude cardboard shapes inside the pressurized flexible bags. This, of course, results in a fan blade of non-uniform wall thickness. Additionally, the cardboard shapes produce a fan blade that is full of wrinkles in the fiberglass layers and cracked resin-rich areas because of the shifting of the fiberglass cloth within the mold as resin is injected through the neck region. In most normal cases, the cardboard is unable to precisely hold and locate the fiberglass layers before resin injection.
It is thus an object of this invention to overcome these deficiencies and to provide a method of manufacturing a hollow, one-piece fan blade that is less labour intensive, is stronger, more aesthetically pleasing to the eye and results in fewer rejects than the methods previously used to construct such fan blades. Another object of this invention is to provide a method that specifically reduces the occurrence of resin-rich areas while also providing support and precise placement and retention of the fiberglass cloths so as to reduce their wrinkling or shifting when the resin is forced into the mold. These and other objects of this invention will become obvious upon further investigation.
SUMMARY OF THE INVENTION
According to one aspect of the present invention there is provided a method of manufacturing a hollow fan blade comprising the steps of laying glass fiber cloths within a lower portion of a mold; placing a flexible inflatable bag on said cloths within said mold; inserting a semi rigid preform conforming to the shape of one side of the blade on top of said flexible bag, said preform being temporarily held together by a suitable resin binder; covering said preform with said cloths or additional cloths; closing said mold and inflating said flexible bag;
injecting resin into said mold around said flexible bag thereby both impregnating said cloths and said preform and replacing said 20 ~37 47 -3a-resin binder in said preform thereby bonding said cloths and said preform together into a single unit; and curing the fan blade, deflating said flexible bag, and removing the fan blade from said mold.
According to a further aspect of the present invention there is provided a method of constructing hollow fan blades comprising the steps of supporting glass fiber material within a mold upon a temporary preform; and injecting said preform and said material with resin, said resin replacing the binder resin of said preform, thereby bonding said preform and said material together to form said fan blade.
According to a still further aspect of the present invention there is provided a molded, hollow fan blade constructed of upper and lower layers of resin-impregnated glass fan fiber cloths and having an internal cavity therein, wherein the improvement comprises a solitary, cured, glass fiber preform within the fan blade and defining a portion of the internal cavity therein, said preform configured to engage and solely support the upper layers of the cloths and comprising a unitary, stationary, curved, panel; and resin binding means for integrally bonding said preform solely to the upper layers of the cloths.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a pictorial view partially broken away of the finished fan blade.
2û43747 Fig. 2 is a pictorial view of the fiberglass preform.
Fig. 3 is a sectional view taken along lines 3-3 of Fig. 2.
Fig. 4 is a sectional view taken along lines 4-4 of Fig. 2.
Fig. 5 is a sectional view taken along lines 5-5 of Fig. 2.
Fig. 6 is a pictorial view of the lay-up operation.
Fig. 7 is a pictorial view of the mold enclosing the preform and flexible bag.
Fig. 8 is a pictorial view of the mold during the curing operation.
DETAILED DESCRIPTION OF THE INVENTION
Referring initially to Fig. 1, there is shown hollow fan blade 10 having a neck portion 12 and an air foil portion 14.
Neck portion 12 is configured with collar 16 for connecting with a rotating shaft or hub (not shown). Air foil portion 14 is configured as needed for the operating conditions, but in any event, its hollow construction is of multi-layered fiberglass.
No metallic internal spar is needed to supply adequate strength for safe operation.
Preform 18, as shown in Fig. 2, is used in the construction of fan blade 10, in fact, preform 18 is designed to eventually become a part of fan blade lO. The curvature of preform 18 can vary as needed with typical curvatures illustrated in Figs. 3, 4, and 5. As can be surmised, preform 18 is designed only to support the upper layers of fiberglass cloths in a mold until they are saturated with resin and cured. The lower layers of the fiberglass cloths will be supported by the bottom half of the mold. Consequently, the entire shape of fan blade 10 need not be supported by preform 18, only the upper half of it.
- 2043747.
Preform 18 is preferably constructed of chopped fiberglass fibers which have been shaped as needed by being blown or a fiberglass mat laid onto a mandril of the desired curvature.
After the required thickness has been achieved, the chopped fiberglass or mat is held together by impregnating it with a light resin binder with this mixture then being oven cured to create the desired semi-rigid preform 18. The light binder resin used to hold preform 18 together is compatible with the resin used during the molding of fan blade 10. After preform 18 is cured, it is stripped off its mandril and used to support the upper layers of the fiberglass cloths in a mold for constructing fan blade 10. Thus, preform 18 is constructed to conform to the finished blade shape for precise fiberglass placement.
Referring now to Figs. 6-8, the steps required to mold fan blade 10 are shown. Initially, the bottom half 20 of mold 22 is laid with varying layers of fiberglass cloths 24 or other fiberglass types. On top of this, flexible bag 26 is placed which will be pressurized once mold 22 is closed. While flexible bag 26 is still deflated, however, preform 18 is positioned on top of it so as to support the upper layers of fiberglass cloths 24 which will be folded around it and/or placed on top of it.
Because preform 18 is able to maintain and precisely position the dry laid-up fiberglass cloths 24 within mold 22, the possibility of wrinkles and/or resin-rich areas within mold 22 are greatly reduced, if not completely eliminated.
After mold 22 is closed and clamped, flexible bag 26 is inflated through neck portion 12 and subsequently sealed thereby also restraining dry fiberglass cloths 24 in place within mold _ -6-22. Upon proper inflation, resin is pumped or injected into mold 22 via neck portion 12 to saturate both preform 18 and the fiberglass cloth layers 24 thereby binding the two together.
Heat is then applied to cure this mixture afterwhich flexible bag 26 is removed after mold 22 is opened to release newly formed fan blade 10.
The use of preform 18 enables fiberglass cloths 24 to be maintained at their optimum position upon the closing of mold 22.
Additionally, preform 18 can be formed into any planform shape, straight or tapered, and can easily accommodate a tapered attachment end (neck portion 12) that normally terminates into a cylindrical clamping area for suitable mounting. With the disclosed resin transfer method or resin injection method of molding, a more aerodynamically efficient, stronger and aesthetically pleasing one-piece fan blade can be manufactured.
Claims (16)
1. A method of manufacturing a hollow fan blade comprising the steps of:
a. laying glass fiber cloths within a lower portion of a mold;
b. placing a flexible inflatable bag on said cloths within said mold;
c. inserting a semi rigid preform conforming to the shape of one side of the blade on top of said flexible bag, said preform being temporarily held together by a suitable resin binder;
d. covering said preform with said cloths or additional cloths;
e. closing said mold and inflating said flexible bag;
f. injecting resin into said mold around said flexible bag thereby both impregnating said cloths and said preform and replacing said resin binder in said preform thereby bonding said cloths and said preform together into a single unit; and g. curing the fan blade, deflating said flexible bag, and removing the fan blade from said mold.
a. laying glass fiber cloths within a lower portion of a mold;
b. placing a flexible inflatable bag on said cloths within said mold;
c. inserting a semi rigid preform conforming to the shape of one side of the blade on top of said flexible bag, said preform being temporarily held together by a suitable resin binder;
d. covering said preform with said cloths or additional cloths;
e. closing said mold and inflating said flexible bag;
f. injecting resin into said mold around said flexible bag thereby both impregnating said cloths and said preform and replacing said resin binder in said preform thereby bonding said cloths and said preform together into a single unit; and g. curing the fan blade, deflating said flexible bag, and removing the fan blade from said mold.
2. The method as set forth in claim 1 further comprising the step of assembling said preform of glass fibers that are held together by said temporary resin binder which dissolves upon the bonding of said cloths and said preform.
3. The method as set forth in claim 2 wherein said preform is constructed of chopped or continuous strand glass fibers.
4. The method as set forth in claim 2 wherein said preform is constructed of a glass fiber mat.
5. The method as set forth in claim 2 wherein said fan blade is of hollow one-piece construction comprising both a neck portion and an air foil portion.
6. A method of constructing hollow fan blades comprising the steps of:
a. supporting glass fiber material within a mold upon a temporary preform; and, b. injecting said preform and said material with resin, said resin replacing the binder resin of said preform, thereby bonding said preform and said material together to form said fan blade.
a. supporting glass fiber material within a mold upon a temporary preform; and, b. injecting said preform and said material with resin, said resin replacing the binder resin of said preform, thereby bonding said preform and said material together to form said fan blade.
7. The method as set forth in claim 6 further comprising the steps of assembling said preform of glass fibers that are held together by a temporary resin binder which dissolves during construction of said blade.
8. The method as set forth in claim 7 wherein said preform is constructed of chopped or continuous strand glass fibers.
9. The method as set forth in claim 7 wherein said preform is constructed of a glass fiber mat.
10. The method as set forth in claim 7 wherein said fan blade is of hollow one-piece construction comprising both a neck portion and an air foil portion.
11. A molded, hollow fan blade constructed of upper and lower layers of resin-impregnated glass fan fiber cloths and having an internal cavity therein, wherein the improvement comprises:
a. a solitary, cured, glass fiber preform within the fan blade and defining a portion of the internal cavity therein, said preform configured to engage and solely support the upper layers of the cloths and comprising a unitary, stationary, curved, panel; and, b. resin binding means for integrally bonding said preform solely to the upper layers of the cloths.
a. a solitary, cured, glass fiber preform within the fan blade and defining a portion of the internal cavity therein, said preform configured to engage and solely support the upper layers of the cloths and comprising a unitary, stationary, curved, panel; and, b. resin binding means for integrally bonding said preform solely to the upper layers of the cloths.
12. The apparatus as set forth in claim 11 wherein said preform is initially held together by a temporary resin binder and wherein said resin binding means replaces said temporary resin binder in the finished fan blade.
13. The apparatus as set forth in claim 12 wherein said preform is constructed of chopped glass fibers.
14. The apparatus as set forth in claim 12 wherein said preform is constructed of continuous strand glass fibers.
15. The apparatus as set forth in claim 12 wherein said preform is constructed of a glass fiber mat.
16. The apparatus as set forth in claim 12 wherein the fan blade is of hollow one-piece construction comprising both a neck portion and an air foil portion.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US07/546,806 US5156786A (en) | 1990-07-02 | 1990-07-02 | Method for manufacuring fan blades |
| US07/546,806 | 1990-07-02 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2043747A1 CA2043747A1 (en) | 1992-01-03 |
| CA2043747C true CA2043747C (en) | 1995-06-27 |
Family
ID=24182092
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002043747A Expired - Fee Related CA2043747C (en) | 1990-07-02 | 1991-06-03 | Method of manufacturing fan blades |
Country Status (12)
| Country | Link |
|---|---|
| US (1) | US5156786A (en) |
| EP (1) | EP0465169B1 (en) |
| JP (1) | JPH0737052B2 (en) |
| CN (1) | CN1034642C (en) |
| AU (1) | AU634377B2 (en) |
| BR (1) | BR9102099A (en) |
| CA (1) | CA2043747C (en) |
| DE (1) | DE69114926T2 (en) |
| ES (1) | ES2080255T3 (en) |
| ID (1) | ID826B (en) |
| MX (1) | MX173885B (en) |
| ZA (1) | ZA913305B (en) |
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| US6143236A (en) * | 1994-02-09 | 2000-11-07 | Radius Engineering, Inc. | Method for manufacturing composite shafts with injection molded, rigidized bladder with varying wall thickness |
| US5741450A (en) * | 1996-01-16 | 1998-04-21 | Hudson Products Corporation | Method of and apparatus for molding a hollow fan blade |
| FR2760681B1 (en) * | 1997-03-12 | 1999-05-14 | Alternatives En | METHOD FOR MANUFACTURING A LARGE-DIMENSIONAL PART OF COMPOSITE MATERIAL AND PROPELLER BLADE, PARTICULARLY A WIND TURBINE, MANUFACTURED ACCORDING TO THIS PROCESS |
| US6319346B1 (en) | 1997-04-23 | 2001-11-20 | Radius Engineering, Inc. | Method for manufacture of composite aircraft control surfaces |
| US6340509B1 (en) | 1997-04-23 | 2002-01-22 | Radius Engineering, Inc. | Composite bicycle frame and method of construction thereof |
| US6248024B1 (en) | 1997-04-23 | 2001-06-19 | Radius Engineering, Inc. | Composite golf club head |
| US6475424B1 (en) | 1998-05-14 | 2002-11-05 | Cambridge Industries, Inc. | Multi-process molding method and article produced by same |
| US6712584B2 (en) * | 2000-04-21 | 2004-03-30 | Revcor, Inc. | Fan blade |
| US20040258531A1 (en) * | 2000-04-21 | 2004-12-23 | Ling-Zhong Zeng | Fan blade |
| US6814545B2 (en) * | 2000-04-21 | 2004-11-09 | Revcor, Inc. | Fan blade |
| JP2003094448A (en) * | 2001-09-25 | 2003-04-03 | Toray Ind Inc | Manufacturing method for frp hollow structure |
| US6942457B2 (en) * | 2002-11-27 | 2005-09-13 | Revcor, Inc. | Fan assembly and method |
| US20090146433A1 (en) * | 2007-12-07 | 2009-06-11 | General Electric Company | Method and apparatus for fabricating wind turbine components |
| CN101903240B (en) * | 2007-12-18 | 2013-08-07 | 贝尔直升机泰克斯特龙公司 | Rotor blade and method of making same |
| FR2940173B1 (en) * | 2008-12-23 | 2013-02-08 | Snecma | METHOD FOR MANUFACTURING A SHAPE PIECE THROUGH 3D FABRIC AND SHAPE PIECE THUS OBTAINED |
| DK2441951T3 (en) * | 2010-10-13 | 2017-07-10 | Siemens Ag | Process for manufacturing a wind turbine rotor blade |
| CN101992384B (en) * | 2010-10-26 | 2013-02-06 | 昆山华风风电科技有限公司 | Manufacturing process of shearing rib mold |
| CN102514210A (en) * | 2011-12-12 | 2012-06-27 | 天津工业大学 | Moulding method of composite material prefabricated component |
| CN102806668B (en) * | 2012-07-03 | 2016-05-11 | 徐建昇 | The forming method of fiber fittings |
| US10307975B2 (en) | 2015-07-17 | 2019-06-04 | Rohr, Inc. | Resin-infusion process for composites manufacturing |
| CN105563851A (en) * | 2016-02-04 | 2016-05-11 | 上海晋飞新材料科技有限公司 | Moulding process for fuselage of UAV (Unmanned Aerial Vehicle) |
| DE102017102565A1 (en) * | 2017-02-09 | 2018-08-09 | CG Rail - Chinesisch-Deutsches Forschungs- und Entwicklungszentrum für Bahn- und Verkehrstechnik Dresden GmbH | A method for producing a hollow carrier made of a fiber composite material, a core formed as a hollow body and its use and the use of the hollow carrier made of fiber composite material |
| GB201803802D0 (en) | 2018-03-09 | 2018-04-25 | Rolls Royce Plc | Composite fan blade and manufacturing method thereof |
| FR3109115B1 (en) | 2020-04-10 | 2024-04-05 | Safran Aircraft Engines | METHOD FOR MANUFACTURING A PREFORM FOR A TURBOMACHINE COMPOSITE MATERIAL PART AND CORRESPONDING PART |
| CN113119492B (en) * | 2021-04-13 | 2022-05-31 | 山东医学高等专科学校 | Preparation method of marine propeller blade fiber reinforced composite material |
| CN113492542A (en) * | 2021-07-06 | 2021-10-12 | 上海电气风电集团股份有限公司 | Blade pouring process method and pouring system |
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-
1990
- 1990-07-02 US US07/546,806 patent/US5156786A/en not_active Expired - Fee Related
-
1991
- 1991-04-26 AU AU75973/91A patent/AU634377B2/en not_active Ceased
- 1991-05-02 ZA ZA913305A patent/ZA913305B/en unknown
- 1991-05-21 BR BR919102099A patent/BR9102099A/en not_active IP Right Cessation
- 1991-06-03 CA CA002043747A patent/CA2043747C/en not_active Expired - Fee Related
- 1991-06-03 CN CN91103683A patent/CN1034642C/en not_active Expired - Fee Related
- 1991-06-28 DE DE69114926T patent/DE69114926T2/en not_active Expired - Fee Related
- 1991-06-28 JP JP3183884A patent/JPH0737052B2/en not_active Expired - Lifetime
- 1991-06-28 ES ES91305902T patent/ES2080255T3/en not_active Expired - Lifetime
- 1991-06-28 EP EP91305902A patent/EP0465169B1/en not_active Expired - Lifetime
- 1991-07-02 MX MX9100066A patent/MX173885B/en not_active IP Right Cessation
-
1992
- 1992-01-31 ID IDP197692A patent/ID826B/en unknown
Also Published As
| Publication number | Publication date |
|---|---|
| ES2080255T3 (en) | 1996-02-01 |
| JPH04232713A (en) | 1992-08-21 |
| BR9102099A (en) | 1992-01-14 |
| DE69114926T2 (en) | 1996-04-18 |
| EP0465169B1 (en) | 1995-11-29 |
| ID826B (en) | 1996-07-24 |
| JPH0737052B2 (en) | 1995-04-26 |
| ZA913305B (en) | 1992-02-26 |
| CA2043747A1 (en) | 1992-01-03 |
| CN1034642C (en) | 1997-04-23 |
| MX173885B (en) | 1994-04-07 |
| CN1058168A (en) | 1992-01-29 |
| EP0465169A1 (en) | 1992-01-08 |
| US5156786A (en) | 1992-10-20 |
| AU634377B2 (en) | 1993-02-18 |
| AU7597391A (en) | 1992-02-27 |
| DE69114926D1 (en) | 1996-01-11 |
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| Date | Code | Title | Description |
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| EEER | Examination request | ||
| MKLA | Lapsed |