# US 10,767,494 B2 · CMC aerofoil

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- Number: US 10,767,494 B2
- Document ID: US10767494B2
- Status: Granted
- Kind: B2
- Application number: 16/379,925
- Filed: 2019-04-10
- Published: 2019-10-31
- Granted: 2020-09-08
- Earliest claimed: 2018-04-25
- Assignees: ROLLS-ROYCE plc
- Applicants: ROLLS-ROYCE plc
- Inventors: Steven Hillier
- Web page: https://patentgrep.com/patent/US10767494B2

## CPC

- F01D 5/188: {with an insert in the blade cavity to guide the cooling fluid, e.g. forming a separation wall}
- B28B 23/00: Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; {Production of reinforced objects}(B28B21/00 takes precedence; in units for prefabricated buildings B28B7/22)
- F01D 5/282: {Selecting composite materials, e.g. blades with reinforcing filaments}
- F01D 5/284: {Selection of ceramic materials}
- F01D 25/12: Cooling
- F05D 2220/32: in gas turbines
- F05D 2230/31: Layer deposition
- F05D 2240/304: related to the trailing edge of a rotor blade
- F05D 2250/61: corrugated
- F05D 2250/711: convex
- F05D 2250/712: concave
- F05D 2300/6033: Ceramic matrix composites [CMC]
- F05D 2300/612: Foam
- F01D: NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES (machines or engines for liquids F03; non-positive displacement pumps F04D)
- B28B: SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER (foundry moulding B22C; working stone or stone-like material B28D; shaping of substances in a plastic state, in general B29C; making layered products not composed wholly of these substances B32B)
- F05D: INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS

## Abstract

The disclosure relates to a ceramic matrix composite (CMC) aerofoil. Example embodiments include an aerofoil comprising first and second tubular CMC cores (302, 303) extending along a longitudinal axis of the aerofoil; and an outer CMC layer surrounding the first and second tubular CMC cores (302, 303) and defining an outer shape of the aerofoil having leading and trailing edges, wherein fibres within a wall of the second tubular CMC core extend to the trailing edge of the aerofoil.

## Claims

### Claim 1

An aerofoil comprising:
first and second tubular Ceramic Metal Composite (CMC) cores extending along a longitudinal axis of the aerofoil; and
an outer CMC layer surrounding the first and second tubular CMC cores and defining an outer shape of the aerofoil having leading and trailing edges,
wherein fibres within a wall of the second tubular CMC core extend to the trailing edge of the aerofoil.

### Claim 2 (depends on 1)

The aerofoil of claim 1, comprising one or more air cooling passages connecting an inner volume of the second tubular CMC core to an external surface of the aerofoil.

### Claim 3 (depends on 2)

The aerofoil of claim 2, wherein the aerofoil comprises an inner concave external surface and an outer convex external surface, a plurality of air cooling passages connecting the inner volume of the second tubular CMC core to the inner concave external surface.

### Claim 4 (depends on 2)

The aerofoil of claim 2, wherein a plurality of air cooling passages pass through a wall of the second tubular CMC core.

### Claim 5 (depends on 2)

The aerofoil of claim 2, wherein the one or more air cooling passages are defined by one or more gaps between adjacent facing portions of the inner surface of the second tubular CMC core.

### Claim 6 (depends on 5)

The aerofoil of claim 5, comprising an insert between the adjacent facing portions of the inner surface of the second tubular CMC core.

### Claim 7 (depends on 5)

The aerofoil of claim 5, wherein a plurality of air cooling passages are defined by corrugations of the inner surface of the second tubular CMC core.

### Claim 8 (depends on 6)

The aerofoil of claim 6, wherein a plurality of air cooling passages are defined by passages within the insert.

### Claim 9 (depends on 8)

The aerofoil of claim 8, wherein the insert comprises a ceramic foam.

### Claim 10 (depends on 9)

The aerofoil of claim 9, wherein the insert comprises plenums forming the plurality of air cooling passages.

### Claim 11

A method of forming a CMC aerofoil, comprising the steps of:
providing first and second tubular CMC cores;
surrounding the first and second tubular CMC cores with an outer CMC layer to define an outer shape of the aerofoil having leading and trailing edges, wherein fibres within a wall of the second tubular CMC core extend to the trailing edge of the aerofoil; and
consolidating the first and second CMC cores with the outer CMC layer to form the CMC aerofoil.

### Claim 12 (depends on 11)

The method of claim 11, comprising the step of forming one or more air cooling passages connecting an inner volume of the second tubular CMC core to an external surface of the aerofoil.

### Claim 13 (depends on 12)

The method of claim 12, wherein the aerofoil comprises an inner concave external surface and an outer convex external surface, the method comprising forming a plurality of air cooling passages connecting the inner volume of the second tubular CMC core to the inner concave external surface.

### Claim 14 (depends on 12)

The method of claim 12, comprising forming a plurality of air cooling passages passing through a wall of the second tubular CMC core.

### Claim 15 (depends on 12)

The method of claim 12, wherein the one or more air cooling passages are defined by one or more gaps between adjacent facing portions of the inner surface of the second tubular CMC core.

### Claim 16 (depends on 15)

The method of claim 15, comprising providing an insert between the adjacent facing portions of the inner surface of the second tubular CMC core.

### Claim 17 (depends on 15)

The method of claim 15, comprising forming a plurality of air cooling passages by corrugations of the inner surface of the second tubular CMC core.

### Claim 18 (depends on 16)

The method of claim 16, wherein a plurality of air cooling passages are defined by passages within the insert.

### Claim 19 (depends on 1)

The method of claim 1, wherein the insert comprises a ceramic foam.

### Claim 20 (depends on 19)

The method of claim 19, wherein the insert comprises plenums forming the plurality of air cooling passages.