Method of fabricating hollow composite airfoils

Details Method of fabricating hollow composite airfoils Method of fabricating hollow composite airfoils

B - Operations, Transporting

64

C

260/150, 244/98

B64C 3/20 (2006.01)

Patent

CA 1284482

HOLLOW COMPOSITE AIRFOILS WITH CORRUGATED INTERNAL SUPPORT STRUCTURE AND METHOD OF FABRICATING SAME. ABSTRACT OF THE DISCLOSURE A hollow composite airfoil with an integral internal laminated corrugated support structure is formed by disposing silicone rubber mandrels in the corrugations of the laminated support structure to form a core assembly having a desired aerodynamic shape, then stacking on both sides of the core assembly laminae of a composite material (of which the support structure may also be formed), with the stacks overlapping adjacent the leading and trailing edges of the core assembly. Heat and pressure are then applied to the core assembly with the laminae thereon to bond together in a single step the laminae of each stack, and the two stacks to each other and to the support structure to form a continuous shell around the core assembly. The mandrels are then removed. One open end of the resulting hollow airfoil is plugged and that end is inserted into a recess in a mounting platform with a predetermined substantially uniform clearance space therebetween. An elastomeric material is then injected into the clearance space for filling it, and then cured to bond the platform to the airfoil. A polyurethane sheet may be wrapped around the airfoil and cured. A vibration damping polyurethane layer may also be disposed between the core assembly and the composite laminae before bonding thereof. Vibration damping polyurethane layers may also be interleaved with the laminae of the support structure.

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