Rolls-Royce Corporation

Matthew Paul Jevons

Kristofer John Bottome

Ian Colin Deuchar Care

Robert C Backhouse

Darren Ivor James

Gordon Kalwak

There is disclosed a method of fabricating a composite structure (). The method comprises the steps of: providing a pair of preforms (), each comprising a plurality of reinforcing fibers (); providing an intermediate layer () of resiliently deformable material between said preforms () to space said preforms apart from one another such that each preform () bears against a respective side () of the intermediate layer (); providing a curable matrix material around said fibers (); and curing said matrix material to form said plastic composite structure (). Also disclosed is a composite structure () having at least two layers of fiber-reinforced plastic () which are bonded to respective sides () of an intermediate layer () of resiliently deformable material, the intermediate layer () being arranged to space the two layers of fiber-reinforced plastic () from one another.

Composite structure and a method of fabricating the same

A composite component having a body formed from a plurality of fiber reinforced non-metallic layers. The body includes a delamination region configured so as to permit delamination; and a deflector region configured so as to resist delamination. In the event of delamination, delamination is deflected to and continues to propagate in the delamination region.

Composite component

A method of providing through-thickness reinforcement of a laminated material which includes a matrix material including a step of creating a locally heated zone in the laminated material so as to locally soften the matrix material by focussing a set of at least two energy beams at a location where through-thickness reinforcement is required and a step of inserting a reinforcement element through the thickness of the laminated material at the location of the locally heated zone to through-thickness reinforce the laminated material.

Method of through-thickness reinforcing a laminated material

A retainer plate is provided for retaining a dovetail root of a fan blade of a gas turbine engine in a corresponding axially-extending slot in the rim of a fan disc. In use, the plate locates in a cavity formed at an end of the slot such that a first side of the plate is arranged for contact with an axial end face of the dovetail root and an opposite second side of the plate is arranged for contact with an abutment surface of the cavity to limit axial movement of the root along the slot. The retainer plate is a unitary component and has a layered structure including a first layer at the first side of the plate, a second layer at the second side of the plate, and an intermediate layer between the first and the second layers.

Retainer plate

A retainer plate is provided for retaining a dovetail root of a fan blade of a gas turbine engine in a corresponding axially-extending slot in the rim of a fan disc. In use, the plate locates in a cavity formed at an end of the slot such that a first side of the plate is arranged for contact with an axial end face of the dovetail root and an opposite second side of the plate is arranged for contact with an abutment surface of the cavity to limit axial movement of the root along the slot. The retainer plate is formed from fiber-reinforced composite material, at least a portion of the composite material being reinforced by 3D-woven fiber tows.

A method of through-thickness reinforcing a laminated material is disclosed, in which a reinforcing element is coated with a thermoplastic layer. The reinforcing element is inserted into a base material, and a matrix material, such as a polymeric, is included in the base material. The combination is then cured, or heated, such that the thermoplastic layer and the matrix material diffuse into each other, thereby forming an interphase region around the reinforcing element. This interphase region helps to prevent cracks from propagating from the reinforcing element.

Method of manufacturing a composite material including a thermoplastic coated reinforcing element

The present invention relates to an aerofoil having an erosion resistant leading edge. The aerofoil comprises an aerofoil main body portion and a leading edge portion. The leading edge portion comprises a plurality of functionally distinct parts, including at least; a first part for resisting abrasion of the leading edge portion, and a second part for resisting a bending force applied to the leading edge portion, and located behind the first part.

Aerofoil with erosion resistant leading edge

A layered composite component is disclosed, the component including: a plurality of stacked layers defining a component thickness between opposed component surfaces and at least one reinforcing element extending from each of the opposed component surfaces the reinforcing elements extending at least partially through the component thickness. Another layered composite component is also disclosed, the component including: a plurality of stacked layers defining a plane and having a primary in-plane axis, wherein the at least one block array of reinforcing elements extends into the component along a reinforcing direction that is angled with respect to the plane of the stacked layers, and wherein the at least one block array is angled in the plane of the stacked layers with respect to the primary axis.

Layered composite component

The present invention relates to an aerofoil blade comprising a root, a tip, a leading edge and a trailing edge. At least part of the tip and at least a part of the trailing edge of the blade are reinforced by at least one portion of drapable reinforcing material wrapped around the tip and trailing edge.

Reinforced composite aerofoil blade

An airfoil has a hollow shell providing external airfoil surfaces, and a corrugated core within the shell. The core contacts inner surfaces of the shell to support the shell. The airfoil is formed by consolidating a hollow shell pre-form and a corrugated core pre-form. At least a part of the hollow shell has a leading edge shell portion and/or a trailing edge shell portion which, before consolidation of the pre-forms, is a unitary body having a shape which wraps around the respective edge.

Airfoil

The present invention relates to a reinforcing tip cap for an aerofoil blade. The tip cap comprises a body for attaching to the tip of an aerofoil blade and a plurality of abrading elements fixed in the body for abrading a surface against which the tip cap rubs in use.

Composite aerofoil blade with wear-resistant tip

The present invention relates to an actuatable seal () for an aerofoil blade tip, for providing a seal between the blade tip () and an adjacent surface () over which the blade tip passes in use. The seal comprises a flexible member that is arranged in use to be mounted on the tip of a rotating aerofoil blade and to flex towards the surface under the action of centrifugal force when the blade rotates. The seal further comprises an actuator means provided on the flexible member and operably arranged in use to deflect at least a portion of the flexible member away from the surface.

Actuatable seal for aerofoil blade tip

The present invention relates to an aerofoil () comprising a leading edge portion () and a flexible thin-walled portion () that is rearwards of the leading edge portion, defining a cavity (), and a shape-forming insert () for inserting into the cavity. The shape-forming insert at least partly defines the profile of the aerofoil such that changing the shape of the insert changes the profile of the aerofoil.

Adjustable camber aerofoil

The present invention relates to a Test apparatus () for testing the interaction between through-thickness compression and shear in a test piece (). The apparatus comprises first and second chocks () arranged in use to securely retain a test piece, and first and second races () which can be controllably urged towards each other to transmit a known force to the first and second chocks. The first and second chocks and the test piece together form a substantially cylindrical body of a first diameter and. The first and second races define therebetween a substantially cylindrical space of a second diameter for accommodating the chocks, and wherein the second diameter is greater than the first diameter.

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Derby, United Kingdom

Matthew Paul Jevons