General Electric Company

Jack W Baldwin

Bruce Clark Busbey

Christopher Charles Glynn

David William Crall

Ian Francis Prentice

James Michael Forrester

Charles Richard Evans

Leslie L Langenbrunner

Richard Thomas Price

John A Ravenhall

Scott A Welsh

Brian K Gracias

Bradley R Love

The present invention provides a process for the lay-up of a composite laminate article, the article produced by this process, and the apparatus used to produce the composite laminate article. The composite laminate article may be, for example, an airfoil, particularly useful as a fan blade in a large high bypass ratio turbofan engine, wherein the blade is generally regarded as large and having a high degree of twist. In a preferred embodiment, the present invention provides a process for laying up a composite laminate article comprising a) reading a data set to enable the projection of an image of a ply section onto a work surface, the image indicating a ply section target point; b) laying up a ply section of composite laminating material within the image, wherein the ply section first contacts the work surface at the target point; and c) repeating steps (a)-(b) until the composite laminate article is complete. In a second preferred embodiment, the present invention provides for a lamination apparatus for use in making a composite laminate article comprising a work surface for receiving, in a predetermined sequence, a plurality of ply sections of composite laminating material; a laser projection system using predetermined projection points for outlining an image of a ply section onto the work surface, the image further indicating a ply section target point for making first contact of the ply section with the work surface; and a data set for providing the predetermined projection points to the laser projection system.

Laser projection system to facilitate layup of complex composite shapes

The present invention provides for a method of manufacturing a preform for a RTM molding process that will increase both the handling capability of the preform and the final part quality. The invention consists of applying a patterned discontinuous layer of liquid resin over at least one side of a layer of reinforcing fibers. The resin film can consist of a homogeneous liquid, an aqueous dispersion or a melted resin applied at an elevated temperature. In one embodiment, there is present a roller having a patterned surface. Liquid resin is applied to the surface of the patterned roller via a second roller. The layer of reinforcing fibers is passed by the roller in such a fashion that the resin from the pattern on the surface of the roller is transferred to the layer of reinforcing fibers. The contact of the roller with the layer of reinforcing fibers is sufficient to force some of the resin into the fibers themselves. After the resin is applied, the layer of reinforcing fibers with resin is passed through an additional process to cause the resin to turn into a solid flexible coating. The layer of fiber is then wrapped onto a cardboard roll or similar type material and packaged for storage or shipment.

Method of preparing preforms for RTM molding processes

A fiber reinforced composite article is made by providing a plurality of layers of first, substantially dry, unimpregnated reinforcing fibers, sometimes called in-plane fibers. Such layers are stacked into a preform of a stack of layers. While in the dry, unimpregnated condition, a plurality of spaced apart second reinforcing members are inserted into the preform at an angle, for example transversely, to the stack of layers. In this condition, the preform is impregnated with a matrix about the first reinforcing fibers and the second reinforcing members. The article product comprises the plurality of stacked layers of the first reinforcing fibers and the plurality of the spaced apart second reinforcing members disposed beside or adjacent the first reinforcing fibers, with a substantially solid matrix disposed about the reinforcing fibers and members.

Method for making a fiber reinforced composite article and product

A fan blade includes a spar having first and second opposite sides. The spar sides include a fatigue-life enhanced surface layer, with the spar first side having a cavity bounded in part by the surface layer. A skin closes the cavity and is bonded to the spar for maintaining the enhanced surface layer inside the cavity.

Adhesive bonded fan blade

A fan assembly for a gas turbine engine for aircraft has a stator casing made of a first material and an annular abradable seal structure made of a second material comprising an epoxy foam having heat expandable, thermoplastic microballoons filled with a chemical which expands when the second material is cured such that the second material bonds directly to the stator casing upon curing thereby minimizing the number of processing steps during manufacture.

Seal including a non-metallic abradable material

A composite article includes a plurality of laminates each having structural fibers bonded in a matrix, and an adhesive film disposed between and bonding together adjacent ones of the laminates. In an exemplary embodiment, the laminates and the interleaved adhesive films form a facesheet which is joined to a core for forming an impact resistant fan case impact liner for a gas turbine engine. The impact liner may be integrated with a sound suppression liner.

Impact resistant fan case liner

Inserting a woven composite layer between laminates of composite material layers where the insert layer comprises composite, carbon fibers woven in a three dimensional weave. The woven insert is injected with a resin material and partially cured prior to deposition of the composite layers. The complete blade is then molded and cured as a unit.

Growing community of inventors

West Chester, OH, United States of America

Jack W Baldwin