Rolls-royce Corporation

Rolls-royce Corporalion

Benedict N Hodgson

Robert W Heeter

Matthew J Kappes

Jonathan M Rivers

Jeffrey P Henkle

Jeff Higbie

Christopher D Hall

Eric William Engebretsen

Matthew Jordan

Matthew Joseph Jordan

Eric W Engebretsen

Christopher Hall

Matthew Kappes

Rivers Jonathan M M

The disclosure describes acoustic panels (such as for gas turbine engines) and techniques for forming acoustic panels. In some examples, the acoustic panel comprises a coversheet comprising an outer face, an inner face, and a plurality of apertures extend from the outer face to the inner face. The acoustic panel also comprises a 3D printed support layer comprising a polymer and defining a plurality of cell openings, wherein a first side of the support layer opposite the cell openings is coincident with the inner face of the coversheet, and wherein the 3D printed support layer is 3D printed directly onto the inner face of the coversheet.

Acoustic panel with 3D printed cell structure support layer

In some examples, acoustic panels (such as for gas turbine engines) and techniques for forming acoustic panels. In some examples, the acoustic panel including a coversheet including an outer face, an inner face, and a plurality of apertures extend from the outer face to the inner face. The acoustic panel also includes a 3D-printed support layer including a lattice structure formed at least partially of a polymer, the lattice structure defining a plurality of cells of the support layer, wherein a first side of the support layer is coincident with the inner face of the coversheet.

3D printed acoustic panel with lattice structure support layer

Composite liners (such as acoustic panels, fan track liners, and/or ice impact panels or boxes for turbofan engines) and techniques for forming composite liners. In some examples, the composite liner includes at least one region comprising a reinforcement architecture comprising a matrix material, a plurality of relatively tough polymer-based reinforcement elements, and a plurality of second reinforcement elements. The plurality of relatively tough polymer-based reinforcement elements and the plurality of second reinforcement elements are embedded in the matrix material.

Composite liners for turbofan engines

A composite aerofoil may include an aerofoil body defining a leading edge and a trailing edge, wherein the body comprises a composite material including a plurality of relatively higher-modulus reinforcement elements, a plurality of relatively tougher polymer-based reinforcement elements, and a matrix material substantially encapsulating the plurality of relatively higher-modulus reinforcement elements and the plurality of relatively tougher polymer-based reinforcement elements. The plurality of relatively higher-modulus reinforcement elements are different from the plurality of relatively tougher polymer-based reinforcement elements. The disclosure also describes techniques for forming composite aerofoils.

Composite aerofoils

The disclosure describes composite nosecones and techniques for forming composite nosecones including a matrix material, relatively higher-modulus reinforcement elements, and relatively tougher polymer-based reinforcement elements. An example composite nosecone includes a body substantially symmetrical around a central axis. The body includes a side wall defining a diameter of the body that increases from a forward side of the body to an aft side of the body. The body includes a composite material including a plurality of relatively higher-modulus reinforcement elements, a plurality of relatively tougher polymer-based reinforcement elements, and a matrix material substantially encapsulating the plurality of relatively higher-modulus reinforcement elements and the plurality of relatively tougher polymer-based reinforcement elements. The plurality of relatively higher-modulus reinforcement elements are different from the plurality of relatively tougher polymer-based reinforcement elements.

Composite nosecone

According to one aspect, a fan containment case for a gas turbine engine is provided which includes a barrel having a first band of material on an outside of the barrel. The first band is made of carbon fiber composite. The barrel further includes a second band of material inboard of the fan case and made of poly p-phenylene-2,6-benzobisoxazole (PBO) composite. The barrel also includes a third band of material made of carbon fiber composite inboard of the second band.

Fan containment case for a gas turbine engine

According to one aspect, a fan blade containment apparatus for turbofan engines includes a containment hook and a fan case barrel. The containment hook and the fan case barrel are formed from composite materials, and the containment hook is attached to the fan case barrel such that the containment hook contains forward motion of a fan blade during a fan blade off event. The apparatus further includes the containment hook being arranged to shorten the axial length of the fan case barrel.

Containment hook for composite fan case

A leading edge member for a composite vane of a gas turbine engine. The leading edge member includes a first leg and a second leg. The first leg includes a proximal end joined to a proximal end of the second leg.

Airfoil with leading edge reinforcement

An aggregate vane assembly includes a core vane assembly encircling a central longitudinal axis and having a plurality of core vanes each extending radially between an inner hub and an outer band. The aggregate vane assembly also includes a bypass vane assembly disposed on a radially opposite side of the outer band relative to the plurality of core vanes. The aggregate vane assembly also includes a splitter ring positioned proximate to the first forward end. The aggregate vane assembly also includes at least one retention plate overlapping a forward end of the at least one bypass vane along the central longitudinal axis and also overlapping at least a portion of the splitter ring along the central longitudinal axis.

Aggregate vane assembly

A composite component includes an inner core formed from a first composite material having discontinuous fibers. An outer sleeve is formed from a second composite material different from the first, and having continuous fibers. The outer sleeve generally surrounds and is bonded or otherwise connected to the inner core. The component is made by injecting or otherwise introducing thermoplastic fiber composite material including chopped or otherwise discontinuous fibers into a mold to form the inner core having a first portion with smooth surfaces and integrally joined to a second portion with bumps and ridges. The injected thermoplastic fiber composite material is cured and then removed from the mold. A layup including one or more surface plies of a thermoset continuous fiber composite material is then applied to the smooth first portion of the core. The surface plies then are compressed and cured in a mold.

Airfoil assembly and method of forming same

An airfoil or vane for a combustive power plant includes an inner core formed from a first composite material having discontinuous fibers. An outer sleeve is formed from a second composite material having continuous fibers. The first composite material is different from the second composite material. The outer sleeve generally surrounds and is bonded or otherwise connected to the inner core. A method of fabrication includes injecting or otherwise introducing thermoplastic fiber composite material including chopped or otherwise discontinuous fibers into a mold to form the core and platforms of an airfoil assembly. The injected thermoplastic fiber composite material is then cured in the mold. The cured thermoplastic fiber composite material is then removed from the mold. A layup including one or more surface plies of a thermoset continuous fiber composite material is then applied to the core material. The surface plies are then compressed and cured in a mold.

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Indianapolis, IN, United States of America

Benedict N Hodgson