Attachment of composite article

Information

  • Patent Grant
  • 9777579
  • Patent Number
    9,777,579
  • Date Filed
    Monday, December 10, 2012
    12 years ago
  • Date Issued
    Tuesday, October 3, 2017
    7 years ago
Abstract
A composite article including composite component extending heightwise from a component base to a component tip and lengthwise between spaced apart component first and second edges. Component plies having widthwise spaced apart ply first and second sides and ply edges therebetween. Component mounted on a spar which includes a shank extending heightwise into the composite component, tab at upper end of shank and substantially or fully embedded in the composite component, and tab tip. Ply edges of at least a first portion of the plies directly or indirectly contacting or pressing against the tab. Ply edges of at least a second portion of the plies may directly or indirectly contact or press against the tab tip. Ply edges of first portion may press against one or more indented or recessed surfaces in the tab. The composite article may be a composite blade or vane including a composite airfoil.
Description
BACKGROUND OF THE INVENTION

Field of the Invention


The invention relates to gas turbine engine composite airfoils and, particularly, for metallic attachments for composite airfoils for mounting in aircraft gas turbine engines.


Description of Related Art


Bypass gas turbine engines of the turbofan type generally includes a forward fan and booster compressor, a middle core engine, and an aft low pressure power turbine. A low pressure turbine rotatably drives the fan and booster compressor via a low pressure shaft, all of which form the low pressure rotor. Composite airfoils have been developed for and used in blades for rotatable stages of the booster compressor and in stator vanes disposed between and upstream and downstream of the blades as well in other sections of the engine such as in the fan section (fan outlet guide vanes).


It is known to manufacture aircraft gas turbine engine blade and vane airfoils from composite materials. It is difficult to attach the composite airfoils to a metallic attachment for mounting the blade or vane to a metallic rotor or stator portion of the engine. This is a challenge due to the magnitude of loads and limited size of the components. Typically, the attachments of these composite parts are the challenging part of that implementation. Typically, it is desired to have an integral composite/metallic system that takes advantage of the composite weight reduction and complex machining of a metallic interface. Joining these two systems in the past has been by simple adhesive bonds. These bonds are subject to forces and moments that tend to dislodge the composite airfoils from a metallic mount of the blade or vane.


It is highly desirable to provide mounts for securely and robustly mounting composite airfoils in both gas turbine engine rotor and fan frame assemblies that resist forces and moments that tend to dislodge the composite airfoils from a metallic mount of the blade or vane and that will enhance the life of the airfoils and the fan frame assembly. In a broader sense, it is highly desirable to provide mounts for securely and robustly mounting composite parts that resist forces and moments that tend to dislodge composite elements from metallic mounts on the part.


SUMMARY OF THE INVENTION

A composite article includes a composite component extending heightwise from a component base to a component tip and lengthwise between spaced apart component first and second edges. The composite component includes plies having widthwise spaced apart ply first and second sides and ply edges therebetween. The composite component is mounted on a spar including a shank extending heightwise from below the component base up through the component base into the composite component, a tab at an upper end of shank and substantially or fully embedded in the composite component, the tab including heightwise spaced apart tab base and tab tip, and the ply edges of at least a first portion of the plies directly or indirectly contacting or pressing against the tab.


The composite article may include one or more indented or recessed surfaces in the tab between heightwise spaced apart tab base and tab tip and the ply edges of at least a first portion of the plies directly or indirectly contact or press against the indented or recessed surfaces and one or more indented or recessed surfaces in the tab between heightwise spaced apart tab base and tab tip.


The ply edges of at least a second portion of the plies may directly or indirectly contact or press against the tab tip. The indented or recessed surfaces may define corresponding indentations or recesses having circular cross sections.


The one or more indented or recessed surfaces of the composite article may include one or more widthwise spaced apart indented or recessed surfaces defining a widthwise taper between the tab base. The taper may taper down in thickness from the tab tip towards the tab base. The ply edges of at least a second portion of the plies may directly or indirectly contact or press against the tab tip.


The composite article may include hooking means for hooking some of the plies of the composite airfoil and be disposed along widthwise spaced apart tab first and second sides of the tab. The hooking means includes hooks disposed along lengthwise spaced apart tab first and second edges of the tab and the one or more indented or recessed surfaces include corners between the hooks and the widthwise spaced apart tab first and second sides. The hooks may include continuous leading first and second edge hook disposed along the lengthwise spaced apart tab first and second edges respectively. Another embodiment of the hooks may include alternating first and second side hooks extending alternatingly outwardly from the tab first and second sides respectively along each of the lengthwise spaced apart tab first and second edges. The hooks may be stepped hooks and each of the stepped hooks include hook steps with runs widthwise separated by rises.


The composite article may be a composite blade or vane including a composite airfoil having widthwise spaced apart airfoil pressure and suction sides extending heightwise or spanwise and outwardly from an airfoil base to an airfoil tip and lengthwise or chordwise between spaced apart airfoil leading and trailing edges. The composite airfoil includes plies having widthwise spaced apart ply pressure and suction sides and ply edges therebetween. The composite airfoil is mounted on a spar including a shank extending heightwise from below the airfoil base up through the airfoil base into the composite airfoil. A tab at an upper end of the shank is substantially or fully embedded in the composite airfoil. One or more indented or recessed surfaces are in the tab between heightwise spaced apart tab base and tab tip. The ply edges of at least a first portion of the plies directly or indirectly contact or press against the indented or recessed surfaces. The spar may be metallic.





BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing aspects and other features of the invention are explained in the following description, taken in connection with the accompanying drawings where:



FIG. 1 is a longitudinal part sectional and part diagrammatical view illustration of an exemplary embodiment of an aircraft turbofan gas turbine engine having booster blades and vanes having composite airfoils.



FIG. 2 is a diagrammatical perspective view illustration of a composite article having a metallic shank with an enlarged tab inserted in a composite element of the article.



FIG. 3 is a diagrammatical perspective view illustration of a composite airfoil having a metallic shank with an enlarged tab inserted therein suitable for use with one of the booster blades and vanes illustrated in FIG. 1.



FIG. 4 is an enlarged diagrammatical perspective view illustration of the composite airfoil and the metallic shank illustrated in FIG. 3.



FIG. 5 is a diagrammatical cross sectional view illustration of the composite airfoil and the metallic shank through 5-5 in FIG. 4.



FIG. 6 is a diagrammatical cross sectional view illustration of the composite airfoil and the metallic shank with the tab having hooks at leading and trailing edges of the tab.



FIG. 7 is a diagrammatical cross sectional view illustration of the tab through 6-6 in FIG. 6.



FIG. 8 is a diagrammatical cross sectional view illustration of alternative hooks for the tab illustrated in FIG. 6.



FIG. 9 is a diagrammatical perspective view illustration of a dovetail root for mounting the composite airfoil illustrated in FIG. 3.



FIG. 10 is a diagrammatical side view illustration the dovetail root illustrated in FIG. 9.



FIG. 11 is a diagrammatical perspective view illustration of a short connector between the dovetail root and tab for the composite airfoil illustrated in FIG. 3.



FIG. 12 is a diagrammatical side view illustration the dovetail root illustrated in FIG. 11.



FIG. 13 is a diagrammatical perspective exploded view illustration of a connection between the shank and a stator band for the composite airfoil illustrated in FIG. 3.



FIG. 14 is a diagrammatical cross sectional view illustration the connection illustrated in FIG. 13.



FIG. 15 is a diagrammatical cross sectional view illustration of a stator band and shank for a braze joint connection between the shank and the band for the composite airfoil illustrated in FIG. 3.



FIG. 16 is a diagrammatical cross sectional view illustration of a braze joint connection between the shank and a stator band for the composite airfoil illustrated in FIG. 3.



FIG. 17 is a diagrammatical cross sectional view illustration of a short braze joint connection between the shank and a stator band for the composite airfoil illustrated in FIG. 3.



FIG. 18 is a diagrammatical cross sectional view illustration of a short braze joint connection with a metallurgical bond between the shank and a stator band for the composite airfoil illustrated in FIG. 3.



FIG. 19 is a diagrammatical cross sectional view illustration of a fir tree root connection of the composite airfoil illustrated in FIG. 3.





DETAILED DESCRIPTION OF THE INVENTION

Illustrated in FIG. 1 is an exemplary aircraft turbofan gas turbine engine 10 circumscribed about an engine centerline axis 12 and suitably designed to be mounted to a wing or fuselage of an aircraft. The engine 10 includes, in downstream serial flow communication, a fan 14, a booster or a low pressure compressor 16, a high pressure compressor 18, a combustor 20, a high pressure turbine (HPT) 22, and a low pressure turbine (LPT) 24. The HPT or high pressure turbine 22 is joined by a high pressure drive shaft 23 to the high pressure compressor 18. The LPT or low pressure turbine 24 is joined by a low pressure drive shaft 25 to both the fan 14 and booster or low pressure compressor 16.


In typical operation, air 26 is pressurized by the fan 14 and an inner portion of this air is channeled through the low pressure compressor 16 which further pressurizes the air. The pressurized air is then flowed to the high pressure compressor 18 which further pressurizes the air. The pressurized air is mixed with fuel in the combustor 20 for generating hot combustion gases 28 that flow downstream in turn through the HPT 22 and the LPT 24. Energy is extracted in the two turbines for powering the fan 14, low pressure compressor 16, and the high pressure compressor 18. A flow splitter 34 surrounding the booster compressor 16 immediately behind the fan 14 includes a sharp leading edge which splits the fan air 26 pressurized by the fan 14 into a radially inner stream 27 channeled through the booster compressor 16 and a radially outer stream 29 channeled through the bypass duct 36.


A fan nacelle 30 surrounding the fan 14 is supported by an annular fan frame 32. The low pressure compressor 16 is suitably joined to the fan 14 forward of the fan frame 32, is disposed radially inboard of the annular flow splitter 34, and is spaced radially inwardly from an inner surface of the fan nacelle 30 to partially define an annular fan bypass duct 36 therebetween. The fan frame 32 supports the nacelle 30.


The compressor 16 has rotatable first, second, and third compressor stages 38, 40, 42 with first, second, and third compressor blade rows 48, 50, 52, respectively. Compressor blades 17 of the first, second, and third compressor blade rows 48, 50, 52 extend radially outwardly from a rotatable hub 46 connected to the fan 14. The compressor 16 has non-rotatable first and second vane stages 62, 64 with first and second vane rows 66, 68, respectively. Compressor vanes 65 of the first and second vane stages 62, 64 extend radially inwardly from a non-rotatable shell or outer band 69 or other annular structure fixedly connected to a forward or fan frame 32. The first, second, and third compressor blade rows 48, 50, 52 are interdigitated with the first and second vane rows 66, 68. The compressor blades and vanes 17, 65 may include composite airfoils. It is also known to mount compressor blades having composite airfoils to disks or drums of gas turbine engines.


Illustrated in FIGS. 3-5 is a composite airfoil 72 that is designed for use in a gas turbine engine blade or vane exemplified by the compressor blades and vanes 17, 65 illustrated in FIG. 1 and described above. The composite airfoil 72 includes widthwise spaced apart airfoil pressure and suction sides 71, 73 extending heightwise or spanwise and outwardly from an airfoil base 74 along an airfoil span S to an airfoil tip 76. The exemplary airfoil pressure and suction sides 71, 73 illustrated herein may be concave and convex respectively. The composite airfoil 72 includes lengthwise or chordwise spaced apart airfoil leading and trailing edges LE, TE at or near forward and aft ends 78, 80 of the airfoil 72. A chord C is defined as a line between the airfoil leading and trailing edges LE, TE of an airfoil cross section 85 of the airfoil 72.


The composite airfoil 72 is mounted on a spar 82 including a shank 84 extending from below the airfoil base 74 up through the airfoil base 74 into the composite airfoil 72. The spar 82 may be made of a material substantially harder than that of the composite airfoil 72. The spar material may be metallic. The spar 82 includes a tab 86 at an upper end 87 of the shank 84. The tab 86 is either substantially or fully embedded in the composite airfoil 72 and may be substantially wider than the shank 84 in a generally chordal direction between the airfoil leading and trailing edges LE, TE.


The tab 86 includes widthwise spaced apart tab pressure and suction sides 91, 93 extending outwardly from a tab base 94 to a tab tip 96. The tab pressure and suction sides 91, 93 correspond to the airfoil pressure and suction sides 71, 73. The tab 86 includes widthwise spaced apart tab leading and trailing edges TLE, TTE at or near tab forward and aft ends 88, 90 of the tab 86. The exemplary embodiment of the tab 86 is fully embedded in the composite airfoil 72 and the tab base 94 (as illustrated herein) is flush with the airfoil base 74. The tab 86 may be embedded deeper into the composite airfoil 72 such that the tab base 94 is spaced inwardly of airfoil base 74.


The spar 82 and the tab 86 provide a means to mount the composite airfoil 72 on a rotor or static structure of the engine. The tab 86 is designed to resist forces F and moments M illustrated in FIG. 3 that tend to loosen dislodge the composite airfoil 72 from the spar 82 and the tab 86. The forces F produce the moments M because the vane or blade containing the spar 82 is mounted cantilevered from the rotor or static structure of the engine. Forces F generally act along three orthogonal axis which are indicated herein as a lengthwise or axial first axis A1 which is generally parallel to the chord C between the airfoil leading and trailing edges LE, TE, a widthwise or circumferential second axis A2 which is generally tangential to a circumference defined by a radius R (illustrated in FIG. 1) normal to the engine centerline axis 12, and a heightwise or radial third axis A3 along the radius R. Moments M are indicated as first, second, and third moments M1, M2, M3 about the first, second, and third axes A1, A2, A3 respectively.


The composite airfoil 72 is made up of filament reinforced laminations 100 formed from a composite material lay-up 106 of filament reinforced composite plies 11 (illustrated in FIG. 8). As used herein, the terms “lamination” and “ply” are synonymous. The plies 11 are generally all made from a unidirectional fiber filament ply woven material which may be in the form of a tape or sheet of material. The plies 11 essentially form the composite airfoil 72. Each of the filament reinforced laminations 100 or plies 11 have widthwise spaced apart ply pressure and suction sides 111, 113 and ply edges 114. Two or more of the ply edges 114, at least one ply pressure side 111, and at least one ply suction side 113 directly or indirectly presses against the tab 86 to help mechanically secure the composite airfoil to the tab 86. The ply edges 114 indirectly presses against the tab 86 by pressing against cured or hardened resin filled pocket 118 between the ply edge 114 and the tab 86 (illustrated in FIG. 8). During manufacturing the plies are layed up around and against the spar and tab and then cured.


Referring to FIGS. 3-5, the tab 86 is shaped to provide mechanical locking of the composite airfoil 72 to the tab 86. A first portion 136 of the plies 11 terminate at the tab 86 along the tab 86 and more particularly along one or both of the leading and trailing edges TLE, TTE of the tab 86. Their ply edges 114 directly or indirectly contact or press against the tab 86. A second portion 138 of the plies 11 have ply edges 114 that directly or indirectly contact or press against the tab tip 96 of the tab 86. This mechanically locks the composite airfoil 72 to the tab 86.


The tab 86 has forward and aft indented or recessed surfaces 120, 122 between the tab base 94 and the tab tip 96. The forward and aft indented or recessed surfaces 120, 122 are indented or recessed inwardly into the tab 86 from the tab leading and trailing edges TLE, TTE at or near the tab base 94 and/or the tab tip 96. The forward and aft indented or recessed surfaces 120, 122 are illustrated herein as being along the tab leading and trailing edges TLE, TTE as illustrated in FIG. 4 and being recessed from near both the tab base 94 and the tab tip 96. The recessed surfaces may be inwardly curved and extend lengthwise and spanwise or heightwise. The lengthwise or heightwise forward and aft recessed surfaces 120, 122 define forward and aft indentations or recesses 130, 132 and may have circular cross sections 131 indicated by a radius of curvature RC as illustrated in FIG. 4 along the tab leading and trailing edges TLE, TTE of the tab 86.


The exemplary tab 86 illustrated herein may also have in addition or alone widthwise spaced apart first and second or pressure and suction side recessed surfaces 140, 142 of the tab 86 between the tab base 94 and the tab tip 96 and between the tab leading and trailing edges TLE, TTE as illustrated in FIGS. 4 and 5. The pressure and suction recessed surfaces 140, 142 are along the tab pressure and suction sides 91, 93 respectively of the tab 86. The pressure and suction recessed surfaces 140, 142 are recessed into the tab 86 and away from widthwise spaced apart airfoil pressure and suction sides 71, 73 respectively of the composite airfoil 72. The tab 86 tapers widthwise inwardly from near the tab tip 96 to the tab base 94 as defined by the pressure and suction recessed surfaces 140, 142. The pressure and suction recessed surfaces 140, 142 define pressure and suction side recesses 150, 152 in the tab 86 and a widthwise taper 154 having a narrowing widthwise thickness T. The exemplary embodiment of the taper 154 illustrated herein tapers down in thickness from the tab tip 96 towards the tab base 94.


The composite airfoil 72 includes many of the plies 11 that directly or indirectly press against the forward and aft indented or recessed surfaces 120, 122 of the tab 86 in the forward and aft recesses 130, 132 and in the pressure and suction side recesses 150, 152 as illustrated in FIGS. 4 and 5. This heightwise and widthwise mechanically locks the composite airfoil 72 to the tab 86. A first portion 136 of the plies 11 terminate at the tab 86 in aft recess 132 and their ply edges 114 directly or indirectly contact or press against the tab 86. A second portion 138 of the plies 11 have ply edges 114 that directly or indirectly contact or press against the tab tip 96 of the tab 86. This further helps mechanically lock the composite airfoil 72 to the tab 86.


Illustrated in FIG. 6 is a hooking means 160 for hooking the plies 11 of the composite airfoil 72 to counter a moment M indicated in the FIG. Hooks 162 of hooking means 160 are indicated between the dashed lines and the tab leading and trailing edges TLE, TTE. The hooks 162 may include a long continuous leading edge hook 166 and a long continuous trailing edge hook 168 indicated in solid line in FIG. 7 at the tab leading and trailing edges TLE, TTE respectively.


Alternatively, the hooks 162 may be arranged with alternating pressure and suction side hooks 163, 165 extending alternatingly outwardly from the tab pressure and suction sides 91, 93 along each of the tab leading and trailing edges TLE, TTE as illustrated in FIG. 7. This arrangement of the hooks 162 includes leading edge pressure and suction side hooks 170, 172 extending alternatingly outwardly from the tab pressure and suction sides 91, 93 and trailing edge pressure and suction side hooks 174, 175 extending alternatingly outwardly from the tab pressure and suction sides 91, 93 along the tab leading and trailing edges TLE, TTE respectively. One set of the leading edge pressure side hook 170 and trailing edge suction side hook 175 extending outwardly from the tab pressure and suction sides 91, 93 respectively are indicated in solid line in FIG. 7. An alternating set of the leading suction side hook 170 and trailing edge pressure side hook 174 extending outwardly from the tab suction and pressure sides 93, 91 respectively are indicated in dashed line in FIG. 7. The forward and aft recessed surfaces 120, 122 and the forward and aft indentations or recesses 130, 132 include corners 178 between the forward and aft or pressure and suction trailing edge hook 174, 175 and the widthwise spaced apart tab first and second or pressure and suction sides 91, 93.


Illustrated in FIG. 8 is a stepped hook 180 which is an alternative to the hooks 162 illustrated in FIGS. 6 and 7. The stepped hook 180 includes hook steps 181 with runs 182 widthwise separated by rises 184. The rises 184 have a height H equal to or one or more times larger than a thickness T of the plies 11. The ply edges 114 of the plies 11 in the hook steps 181 directly or indirectly contact or press against the rises 184 to help mechanically secure the composite airfoil to the tab 86. The ply edges 114 indirectly contact or press against the tab 86 by contacting or pressing against cured or hardened resin filled pockets 118 between the ply edges 114 and rises 184.


Illustrated in FIGS. 9-12 are different designs for the blade 200 containing the composite airfoil 72. The shank 84 includes a root 220 attached to and preferably integral with a lower end 222 of the tab 86. The root is used to mount the blade to a rotor hub or disk. The root 220 is illustrated in these FIGS. as a dovetail root 228 including a dovetail 232 as is commonly known in the art. The tab 86 extends upwardly and the dovetail 232 extends downwardly from a platform 226 of the shank 84. A long tab 86 is illustrated in FIGS. 9 and 10 and a shorter tab 86 is illustrated in FIGS. 11 and 12. The longer tab 86 is coextensive with the root 228. Illustrated in FIG. 19 is a fir tree root 230 attached to and preferably integral with a lower end 222 of the shank 84. The fir tree root 230 is another type of root well known in the art and used to mount the blade to a rotor hub or disk.


Illustrated in FIGS. 13 and 14 is a clipped connection 250 of the shank 84 of the spar 82 disposed through a mounting hole 252 in the outer band 69, illustrated in FIGS. 1 and 15. The clipped connection 250 is used to mount a compressor vanes 65 the outer band 69. T-head 254 is located at an upper end 256 of the shank 84 and the tab 86 is located at a lower end 258 of the shank 84. A U-clip 260 is disposed around the shank 84 and between legs 262 of the T-head 254 the outer band 69.


Illustrated in FIGS. 15-18 are brazed connections 270 between the shank 84 of the spar 82 and the outer band 69. An upper end 256 of the shank 84 is disposed through and brazed into an elongated hole 272 in the outer band 69. The brazed connection 270 is illustrated herein for mounting a compressor vanes 65 the outer band 69. Illustrated in FIGS. 16-18 is how the shank 84 may vary in length L even as the tab 86 and the composite airfoil 72 remain unchanged.


Illustrated in FIG. 2 is a more general composite article 370 including a composite component 372 extending heightwise from an component base 374 to an component tip 376 and lengthwise between spaced apart component first and second edges LE, TE. The composite component 372 is made up of filament reinforced laminations 100 formed from a composite material lay-up 106 of filament reinforced composite plies 11 as those illustrated in FIG. 8. Each of the filament reinforced laminations 100 or plies 11 have widthwise spaced apart ply first and second sides 111, 113 and ply edges 114.


Referring to FIG. 2, the composite component 372 is mounted on a spar 82 including a shank 84 extending from below the component base 374 up through the component base 374 into the composite component 372. The spar 82 includes a tab 86 at an upper end 87 of shank 84. The tab 86 is either substantially or fully embedded in the composite component 372 and may be substantially wider than the shank 84 in a generally lengthwise direction between forward and aft edges FE, AE of the composite component 372. The tab 86 includes widthwise spaced apart tab first and second sides 391, 393 extending outwardly from a tab base 94 to a tab tip 96 and lengthwise between spaced apart tab first and second leading and trailing edges TLE, TTE. The tab first and second sides 391, 393 correspond to the ply first and second sides 111, 113. The spar 82, as disclosed above, is made of a material substantially harder than that of the component 372. The spar material may be metallic.


Two or more of the ply edges 114, at least one ply first side 111, and at least one ply second side 113 directly or indirectly press against the tab 86 to help mechanically secure the composite component 372 to the tab 86. The ply edges 114 indirectly press against the tab 86 by pressing against cured or hardened resin filled pocket 118 between the ply edge 114 and the tab 86. The composite component 372 is mounted and mechanically secured to the tab 86 as described above for the composite airfoil 72.


The present invention has been described in an illustrative manner. It is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. While there have been described herein, what are considered to be preferred and exemplary embodiments of the present invention, other modifications of the invention shall be apparent to those skilled in the art from the teachings herein and, it is, therefore, desired to be secured in the appended claims all such modifications as fall within the true spirit and scope of the invention.


Accordingly, what is desired to be secured by Letters Patent of the United States is the invention as defined and differentiated in the following claims:

Claims
  • 1. A composite article comprising: a composite component extending heightwise from a component base to a component tip and lengthwise between spaced apart component first and second edges,the composite component including plies having widthwise spaced apart ply first and second sides and ply edges therebetween,the composite component mounted on a spar including a shank extending heightwise from below the component base up through the component base into the composite component,a tab at an upper end of shank and substantially or fully embedded in the composite component,the tab including heightwise spaced apart tab base and tab tip, andthe ply edges of at least a first portion of the plies directly or indirectly contacting or pressing against the tab.
  • 2. The composite article as claimed in claim 1 further comprising hooking means for hooking some of the plies of the composite airfoil, the hooking means disposed along widthwise spaced apart tab first and second sides of the tab,the hooking means including hooks disposed along lengthwise spaced apart tab first and second edges, andthe hooking means having one or more indented or recessed surfaces including corners between the hooks and the widthwise spaced apart tab first and second sides.
  • 3. The composite article as claimed in claim 2 further comprising the hooks including continuous leading first and second edge hook disposed along the lengthwise spaced apart tab first and second edges respectively.
  • 4. The composite article as claimed in claim 2 further comprising the hooks including alternating first and second side hooks extending alternatingly outwardly from the tab first and second sides respectively along each of the lengthwise spaced apart tab first and second edges.
  • 5. The composite article as claimed in claim 4 further comprising the hooks being stepped hooks and each of the stepped hooks including hook steps with runs widthwise separated by rises.
  • 6. The composite article as claimed in claim 5 further comprising the rises having a height equal to or one or more times greater than a thickness of the plies.
  • 7. The composite article as claimed in claim 1 further comprising the ply edges of at least a second portion of the plies directly or indirectly contacting or pressing against the tab tip.
  • 8. The composite article as claimed in claim 1 further comprising: one or more indented or recessed surfaces in the tab between heightwise spaced apart tab base and tab tip, andthe ply edges of at least a first portion of the plies directly or indirectly contacting or pressing against the indented or recessed surfaces.
  • 9. The composite article as claimed in claim 8 further comprising the ply edges of at least a second portion of the plies directly or indirectly contacting or pressing against the tab tip.
  • 10. The composite article as claimed in claim 8 further comprising the one or more indented or recessed surfaces defining corresponding one or more indentations or recesses having circular cross sections.
  • 11. The composite article as claimed in claim 8 further comprising the one or more indented or recessed surfaces including one or more widthwise spaced apart indented or recessed surfaces defining a widthwise taper between the tab base.
  • 12. The composite article as claimed in claim 11 further comprising the widthwise taper tapering down in thickness from the tab tip towards the tab base.
  • 13. The composite article as claimed in claim 12 further comprising the ply edges of at least a second portion of the plies directly or indirectly contacting or pressing against the tab tip.
  • 14. The composite article as claimed in claim 8 further comprising: hooking means for hooking some of the plies of the composite airfoil,the hooking means disposed along widthwise spaced apart tab first and second sides of the tab,the hooking means including hooks disposed along lengthwise spaced apart tab first and second edges, andthe one or more indented or recessed surfaces including corners between the hooks and the widthwise spaced apart tab first and second sides.
  • 15. The composite article as claimed in claim 14 further comprising the hooks including continuous leading first and second edge hook disposed along the lengthwise spaced apart tab first and second edges respectively.
  • 16. The composite article as claimed in claim 14 further comprising the hooks including alternating first and second side hooks extending alternatingly outwardly from the tab first and second sides respectively along each of the lengthwise spaced apart tab first and second edges.
  • 17. The composite article as claimed in claim 16 further comprising the hooks being stepped hooks and each of the stepped hooks including hook steps with runs widthwise separated by rises.
  • 18. The composite article as claimed in claim 17 further comprising the rises having a height equal to or one or more times greater than a thickness of the plies.
  • 19. A composite blade or vane comprising: a composite airfoil including widthwise spaced apart airfoil pressure and suction sides extending heightwise or spanwise and outwardly from an airfoil base to an airfoil tip and lengthwise or chordwise between spaced apart airfoil leading and trailing edges,the composite airfoil including plies having widthwise spaced apart ply pressure and suction sides and ply edges therebetween,the composite airfoil mounted on a spar including a shank extending heightwise from below the airfoil base up through the airfoil base into the composite airfoil,a tab at an upper end of shank and substantially or fully embedded in the composite airfoil,the tab including spanwise spaced apart tab base and tab tip, andthe ply edges of at least a first portion of the plies directly or indirectly contacting or pressing against the tab.
  • 20. The composite blade or vane as claimed in claim 19 further comprising one or more indented or recessed surfaces in the tab between heightwise spaced apart tab base and tab tip, and the ply edges of at least a first portion of the plies directly or indirectly contacting or pressing against the indented or recessed surfaces.
  • 21. The composite blade or vane as claimed in claim 20 further comprising the ply edges of at least a second portion of the plies directly or indirectly contacting or pressing against the tab tip.
  • 22. The composite blade or vane as claimed in claim 21 further comprising the one or more indented or recessed surfaces defining corresponding one or more indentations or recesses having circular cross sections.
  • 23. The composite blade or vane as claimed in claim 21 further comprising the one or more indented or recessed surfaces including one or more widthwise spaced apart indented or recessed surfaces defining a widthwise taper between the tab base.
  • 24. The composite blade or vane as claimed in claim 23 further comprising the widthwise taper tapering down in thickness from the tab tip towards the tab base.
  • 25. The composite blade or vane as claimed in claim 24 further comprising the ply edges of at least a second portion of the plies directly or indirectly contacting or pressing against the tab tip.
  • 26. The composite blade or vane as claimed in claim 21 further comprising: hooking means for hooking some of the plies of the composite airfoil,the hooking means disposed along widthwise spaced apart tab first and second sides of the tab,the hooking means including hooks disposed along lengthwise spaced apart tab first and second edges, andthe one or more indented or recessed surfaces including corners between the hooks and the widthwise spaced apart tab first and second sides.
  • 27. The composite blade or vane as claimed in claim 26 further comprising the hooks including continuous leading first and second edge hook disposed along the lengthwise spaced apart tab first and second edges respectively.
  • 28. The composite blade or vane as claimed in claim 26 further comprising the hooks including alternating first and second side hooks extending alternatingly outwardly from the tab first and second sides respectively along each of the lengthwise spaced apart tab first and second edges.
  • 29. The composite blade or vane as claimed in claim 28 further comprising the hooks being stepped hooks and each of the stepped hooks including hook steps with runs widthwise separated by rises.
  • 30. The composite blade or vane as claimed in claim 29 further comprising the rises having a height equal to or one or more times greater than a thickness of the plies.
  • 31. The composite blade or vane as claimed in claim 19 further comprising the spar being metallic.
US Referenced Citations (170)
Number Name Date Kind
3628890 Sayre et al. Dec 1971 A
3725981 Pinckney Apr 1973 A
3737250 Pilpel et al. Jun 1973 A
3752600 Walsh et al. Aug 1973 A
3758232 Wallett Sep 1973 A
3778185 Plowman et al. Dec 1973 A
3799701 Rothman Mar 1974 A
3871687 Dockree Mar 1975 A
3883267 Baudier May 1975 A
3903578 Rothman Sep 1975 A
3923422 Ianniello et al. Dec 1975 A
3984962 Krohn Oct 1976 A
4037990 Harris Jul 1977 A
4070127 Loomis et al. Jan 1978 A
4071184 Carlson et al. Jan 1978 A
4110056 Stevenson Aug 1978 A
4142554 Washkewicz et al. Mar 1979 A
4171999 Allen Oct 1979 A
4185472 Presta et al. Jan 1980 A
4205927 Simmons Jun 1980 A
4211589 Fisher et al. Jul 1980 A
4213641 Bennett Jul 1980 A
4236386 Yates et al. Dec 1980 A
4238540 Presta et al. Dec 1980 A
4247255 De Rosa Jan 1981 A
4251309 Class et al. Feb 1981 A
4259382 Schwan Mar 1981 A
4279275 Stanwood et al. Jul 1981 A
4289557 Stanwood et al. Sep 1981 A
4307755 Schmidt et al. Dec 1981 A
4329193 Sznopek et al. May 1982 A
4339230 Hill Jul 1982 A
4362418 Loomis Dec 1982 A
4370372 Higgins et al. Jan 1983 A
4384802 Lo et al. May 1983 A
4385644 Kaempen May 1983 A
4433933 Parsons, Jr. et al. Feb 1984 A
4469730 Burhans Sep 1984 A
4508047 Bordat Apr 1985 A
4556365 Mouille et al. Dec 1985 A
4556592 Bannink, Jr. Dec 1985 A
4569165 Baker et al. Feb 1986 A
4570979 Moore Feb 1986 A
4579475 Hart-Smith et al. Apr 1986 A
4614369 Overath et al. Sep 1986 A
4619470 Overath et al. Oct 1986 A
4647078 Lundy Mar 1987 A
4648800 Fradenburgh et al. Mar 1987 A
4662587 Whitener May 1987 A
4681647 Kondo et al. Jul 1987 A
4701231 Peters et al. Oct 1987 A
4715560 Loyek Dec 1987 A
4722717 Salzman et al. Feb 1988 A
4740100 Saarela et al. Apr 1988 A
4747806 Krude et al. May 1988 A
4783040 Lindberg et al. Nov 1988 A
4784575 Nelson et al. Nov 1988 A
4797064 Ferris et al. Jan 1989 A
4810167 Spoltman et al. Mar 1989 A
4813457 Offringa et al. Mar 1989 A
4875710 Mercado Oct 1989 A
4877376 Sikorski et al. Oct 1989 A
4961687 Bost et al. Oct 1990 A
4966527 Merz Oct 1990 A
4974245 Mioque et al. Nov 1990 A
5009628 Rouillot Apr 1991 A
5015116 Nardone et al. May 1991 A
5041318 Hulls Aug 1991 A
5043217 Peters et al. Aug 1991 A
5067875 Hunter et al. Nov 1991 A
5076601 Duplessis Dec 1991 A
5082314 Aubry et al. Jan 1992 A
5106130 Ellsworth et al. Apr 1992 A
5110260 Byrnes et al. May 1992 A
5118257 Blakeley Jun 1992 A
5129787 Violette et al. Jul 1992 A
5167742 Peters Dec 1992 A
5213379 Taniguchi et al. May 1993 A
5269489 West et al. Dec 1993 A
5279892 Baldwin et al. Jan 1994 A
5281454 Hanson Jan 1994 A
5288109 Auberon et al. Feb 1994 A
5303958 Hyatt et al. Apr 1994 A
5314282 Murphy et al. May 1994 A
5314382 Pfeifer May 1994 A
5318819 Pai Jun 1994 A
5320579 Hoffmann Jun 1994 A
5327963 Vance, Sr. et al. Jul 1994 A
5338611 Lause et al. Aug 1994 A
5340280 Schilling Aug 1994 A
5362112 Hamilton et al. Nov 1994 A
5375978 Evans et al. Dec 1994 A
5378109 Lallo et al. Jan 1995 A
5383692 Watts Jan 1995 A
5383767 Aubry Jan 1995 A
5398975 Simmons Mar 1995 A
5403161 Nealon et al. Apr 1995 A
5407195 Tiitola et al. Apr 1995 A
5429853 Darrieux Jul 1995 A
5431456 Okumura et al. Jul 1995 A
5443099 Chaussepied et al. Aug 1995 A
5458465 Wieser et al. Oct 1995 A
5460416 Freidrich et al. Oct 1995 A
5468033 Dohrmann Nov 1995 A
5505036 Wiles Apr 1996 A
5520422 Friedrich et al. May 1996 A
5536108 Kvalheim Jul 1996 A
5542230 Schuetze Aug 1996 A
5551918 Jones et al. Sep 1996 A
5556565 Kirkwood et al. Sep 1996 A
5560730 Gillard et al. Oct 1996 A
5591084 Poulin et al. Jan 1997 A
5632601 Bodmer et al. May 1997 A
5634771 Howard Jun 1997 A
5685576 Wolfe et al. Nov 1997 A
5716077 Friedrich et al. Feb 1998 A
5725434 Haben et al. Mar 1998 A
5738494 Schmaling Apr 1998 A
5798153 Fay et al. Aug 1998 A
5800128 Bodmer et al. Sep 1998 A
5813467 Anderson et al. Sep 1998 A
5820344 Hamilton et al. Oct 1998 A
5824179 Greig Oct 1998 A
5836825 Yamane Nov 1998 A
5851152 Ilzhoefer et al. Dec 1998 A
5866272 Westre et al. Feb 1999 A
5868886 Alston et al. Feb 1999 A
5895079 Carstensen et al. Apr 1999 A
5944441 Schuetze Aug 1999 A
6039538 Bansemir Mar 2000 A
6042916 Godbehere Mar 2000 A
6068902 Vasiliev et al. May 2000 A
6168379 Bauer Jan 2001 B1
6176681 Stroemberg et al. Jan 2001 B1
6190263 Kimoto et al. Feb 2001 B1
6213719 Violette et al. Apr 2001 B1
6305905 Nagle et al. Oct 2001 B1
6431837 Velicki Aug 2002 B1
6502788 Noda et al. Jan 2003 B2
6735866 Nogueroles et al. May 2004 B2
7087296 Porter Aug 2006 B2
7575417 Finn et al. Aug 2009 B2
8075274 Carvalho Dec 2011 B2
20010050469 Bernhardt Dec 2001 A1
20020008177 Violette Jan 2002 A1
20030067167 Massaria Apr 2003 A1
20030090108 Palsson May 2003 A1
20030134090 Tate Jul 2003 A1
20030205011 Bequet Nov 2003 A1
20030230893 Song et al. Dec 2003 A1
20040061024 Arulf et al. Apr 2004 A1
20040062655 Potter et al. Apr 2004 A1
20040213953 Brantley et al. Oct 2004 A1
20050084379 Schreiber Apr 2005 A1
20050121913 Smahl Jun 2005 A1
20050257847 Francesco et al. Nov 2005 A1
20060083907 Bech et al. Apr 2006 A1
20060113706 Chevin et al. Jun 2006 A1
20060258469 Dewhirst et al. Nov 2006 A1
20070175966 Barnes Aug 2007 A1
20080001396 Nish et al. Jan 2008 A1
20080012329 Dewhirst Jan 2008 A1
20080115454 Xie May 2008 A1
20080228288 Nelson et al. Sep 2008 A1
20080302914 Wagner Dec 2008 A1
20090047100 Keener Feb 2009 A1
20090087259 Bettinger Apr 2009 A1
20090126180 Keener May 2009 A1
20090148647 Jones et al. Jun 2009 A1
20110129348 Parkin et al. Jun 2011 A1
Foreign Referenced Citations (4)
Number Date Country
2458153 May 2012 EP
2664941 Jan 1992 FR
871066 Jun 1961 GB
2249592 May 1992 GB
Non-Patent Literature Citations (6)
Entry
Search Report from PCT/US2013/073506 dated Feb. 20, 2014.
“Design of Composite-Material Plates for Maximum Uniaxial Compressive Buckling Load”, by Timothy L. C. Chen and Charles W. Bert, Oaklahoma Academby of Science Proceedings, Sep. 25, 2012, 104-107.
PCT Search Report and Written Opinion issued in connection with related PCT Application No. PCT/US2013/073501 dated Oct. 8, 2014.
PCT Preliminary Report on Patentability issued in connection with related PCT Application No. PCT/US2013/073501 dated Jun. 25, 2015.
Unofficial English Translation of Chinese Office Action issued in connection with related CN Application No. 201380064601.2 dated Nov. 4, 2015.
Canadian Office Action issued in connection with related CA Application No. 2894155 dated Jun. 2, 2016.
Related Publications (1)
Number Date Country
20140161620 A1 Jun 2014 US