# US 11,078,839 B2 · Composite nosecone > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,078,839 B2 - Document ID: US11078839B2 - Status: Granted - Kind: B2 - Application number: 15/876,574 - Filed: 2018-01-22 - Published: 2019-07-25 - Granted: 2021-08-03 - Earliest claimed: 2018-01-22 - Assignees: ROLLS-ROYCE plc - Applicants: Rolls-Royce Corporation - Inventors: Robert Heeter; Matthew J. Kappes; Benedict N. Hodgson - Web page: https://patentgrep.com/patent/US11078839B2 ## CPC - F02C 7/04: Air intakes for gas-turbine plants or jet-propulsion plants - B29C 70/08: comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers - C08J 5/042: {with carbon fibres} - C08J 5/043: {with glass fibres} - C08L 77/10: Polyamides derived from aromatically bound amino and carboxyl groups of amino-carboxylic acids or of polyamines and polycarboxylic acids - F01D 5/282: {Selecting composite materials, e.g. blades with reinforcing filaments} - F02C 7/05: having provisions for obviating the penetration of damaging objects or particles - B32B 2377/00: Polyamides - C08J 2300/24: Thermosetting resins - C08L 2201/08: Stabilised against heat, light or radiation or oxydation - F05D 2220/32: in gas turbines - F05D 2220/36: specially adapted for the fan of turbofan engines - F05D 2300/431: Rubber - F05D 2300/433: Polyamides, e.g. NYLON - F02C: GAS-TURBINE PLANTS; AIR INTAKES FOR JET-PROPULSION PLANTS; CONTROLLING FUEL SUPPLY IN AIR-BREATHING JET-PROPULSION PLANTS (construction of turbines F01D; jet-propulsion plants F02K; construction of compressors or fans F04; generating combustion products of high pressure or high velocity F23R; using gas turbines in compression refrigeration plants F25B11/00) - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29) - C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06) - F01D: NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES (machines or engines for liquids F03; non-positive displacement pumps F04D) - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - F05D: INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS ## Abstract The disclosure describes composite nosecones and techniques for forming composite nosecones including a matrix material, relatively higher-modulus reinforcement elements, and relatively tougher polymer-based reinforcement elements. An example composite nosecone includes a body substantially symmetrical around a central axis. The body includes a side wall defining a diameter of the body that increases from a forward side of the body to an aft side of the body. The body includes a composite material including a plurality of relatively higher-modulus reinforcement elements, a plurality of relatively tougher polymer-based reinforcement elements, and a matrix material substantially encapsulating the plurality of relatively higher-modulus reinforcement elements and the plurality of relatively tougher polymer-based reinforcement elements. The plurality of relatively higher-modulus reinforcement elements are different from the plurality of relatively tougher polymer-based reinforcement elements. ## Claims ### Claim 1 A composite nosecone comprising: a body substantially symmetrical around a central axis, the body including a side wall defining a diameter of the body that increases from a forward side of the body to an aft side of the body, wherein the body comprises a composite material including a plurality of relatively higher-modulus reinforcement elements, a plurality of relatively tougher polymer-based reinforcement elements, and a matrix material substantially encapsulating the plurality of relatively higher-modulus reinforcement elements and the plurality of relatively tougher polymer-based reinforcement elements, wherein the plurality of relatively higher-modulus reinforcement elements are different from the plurality of relatively tougher polymer-based reinforcement elements, wherein the side wall comprises: a forward annular region comprising a first layer, wherein the forward annular region has a first ratio of relatively higher-modulus reinforcement elements to relatively tougher polymer-based reinforcement elements; and an aft annular region comprising the first layer and a second layer, wherein the aft annular region has a second ratio of relatively higher-modulus reinforcement elements to relatively tougher polymer-based reinforcement elements, and wherein the first ratio is greater than the second ratio. ### Claim 2 (depends on 1) The composite nosecone of claim 1, wherein the plurality of relatively higher-modulus reinforcement elements have a tensile modulus of greater than 60 GPa and an elongation at break of less than 6.0%. ### Claim 3 (depends on 1) The composite nosecone of claim 1, wherein the plurality of relatively higher-modulus reinforcement elements have a tensile modulus of greater than 180 GPa and an elongation at break of less than 6.0%. ### Claim 4 (depends on 2) The composite nosecone of claim 2, wherein the plurality of relatively higher-modulus reinforcement elements comprise at least one of an aromatic polyamide, a carbon fiber, E-glass, or S-glass. ### Claim 5 (depends on 1) The composite nosecone of claim 1, wherein the plurality of relatively tougher polymer-based reinforcement elements have an elongation at break of greater than 6.0%. ### Claim 6 (depends on 5) The composite nosecone of claim 5, wherein the plurality of relatively tougher polymer-based reinforcement elements comprise at least one of a polyamide, a polyester, a polyester terephthalate, a polypropylene, a polyethylene, or a spider silk. ### Claim 7 (depends on 1) The composite nosecone of claim 1, further comprising at least one attachment area integrally formed with the body, wherein the at least one attachment area comprises the first layer and the second layer, and wherein the at least one attachment area is shaped and positioned to attach the composite nosecone to a fan assembly. ### Claim 8 (depends on 1) The composite nosecone of claim 1, wherein the plurality of relatively higher-modulus reinforcement elements comprise relatively higher-modulus filaments, wherein the plurality of relatively tougher polymer-based reinforcement elements comprise relatively tougher polymer-based filaments, and wherein the relatively higher-modulus filaments and relatively tougher polymer-based filaments are together in a hybrid or commingled braid, a hybrid or commingled weave, or a hybrid or commingled winding. ### Claim 9 (depends on 1) The composite nosecone of claim 1, wherein the matrix material comprises a thermoset polymer. ### Claim 10 (depends on 1) The composite nosecone of claim 1, wherein the aft annular region is a second annular region, wherein side wall further comprises: a third annular region aft the second annular region, wherein the third annular region comprises the first layer, the second layer, and a third layer, and wherein the third annular region has a third ratio of relatively higher-modulus reinforcement elements to relatively tougher polymer-based reinforcement elements, wherein the second ratio is greater than the third ratio; and a fourth annular region aft the third annular region, wherein the fourth annular region comprise the first layer, the second layer, the third layer, and a fourth layer, and wherein the fourth annular region has a fourth ratio of relatively higher-modulus reinforcement elements to relatively tougher polymer-based reinforcement elements, wherein the third ratio is greater than the fourth ratio. ### Claim 11 A method of constructing a composite nosecone, the method comprising: defining a nosecone shape with a matrix material, a plurality of relatively higher-modulus reinforcement elements, and a plurality of relatively tougher polymer-based reinforcement elements, wherein the plurality of relatively higher-modulus reinforcement elements are different from the plurality of relatively tougher polymer-based reinforcement elements, wherein the composite nosecone comprises a body substantially symmetrical around a central axis, the body including a side wall defining a diameter of the body that increases from a forward side of the body to an aft side of the body, and wherein the side wall comprises: a forward annular region comprising a first layer, wherein the forward annular region has a first ratio of relatively higher-modulus reinforcement elements to relatively tougher polymer-based reinforcement elements; and an aft annular region comprising the first layer and a second layer, wherein the aft annular region has a second ratio of relatively higher-modulus reinforcement elements to relatively tougher polymer-based reinforcement elements, and wherein the first ratio is greater than the second ratio; and curing a matrix material substantially encapsulating the plurality of relatively higher-modulus reinforcement elements and the plurality of relatively tougher polymer-based reinforcement elements to form the composite nosecone. ### Claim 12 (depends on 11) The method of claim 11, wherein the plurality of relatively higher-modulus reinforcement elements have a tensile modulus of greater than 60 GPa and an elongation at break of less than 6.0%. ### Claim 13 (depends on 12) The method of claim 12, wherein the plurality of relatively higher-modulus reinforcement elements comprise at least one of an aromatic polyamide, a carbon fiber, E-glass, or S-glass. ### Claim 14 (depends on 11) The method of claim 11, wherein the plurality of relatively higher-modulus reinforcement elements have a tensile modulus of greater than 180 GPa and an elongation at break of less than 6.0%. ### Claim 15 (depends on 11) The method of claim 11, wherein the plurality of relatively tougher polymer-based reinforcement elements have an elongation at break of greater than 6.0%. ### Claim 16 (depends on 15) The method of claim 15, wherein the plurality of relatively tougher polymer-based reinforcement elements comprise at least one of a polyamide, a polyester, a polyester terephthalate, a polypropylene, a polyethylene, or a spider silk. ### Claim 17 (depends on 11) The method of claim 11, wherein the composite nosecone further comprises at least one attachment area integrally formed with the body, wherein the at least one attachment area comprises the first layer and the second layer, and wherein the at least one attachment area is shaped and positioned to attach the composite nosecone to a fan assembly. ### Claim 18 (depends on 11) The method of claim 11, wherein the plurality of relatively higher-modulus reinforcement elements comprise relatively higher-modulus filaments, wherein the plurality of relatively tougher polymer-based reinforcement elements comprise relatively tougher polymer-based filaments, and wherein the relatively higher-modulus filaments and relatively tougher polymer-based filaments are together in a hybrid or commingled braid, a hybrid or commingled weave, or a hybrid or commingled winding. ### Claim 19 (depends on 11) The method of claim 11, wherein the defining the composite nosecone comprises: pre-impregnating the plurality of relatively higher-modulus reinforcement elements and the plurality of relatively tougher polymer-based reinforcement elements with the matrix material; and at least one of filament winding the pre-impregnated plurality of relatively higher-modulus reinforcement elements and the pre-impregnated plurality of relatively tougher polymer-based reinforcement elements onto a mandrel or layering the pre-impregnated plurality of relatively higher-modulus reinforcement elements and the pre-impregnated plurality of relatively tougher polymer-based reinforcement elements on a mold. ### Claim 20 A composite nosecone comprising: a body substantially symmetrical around a central axis, the body including a side wall defining a diameter of the body that increases from a forward side of the body to an aft side of the body, wherein the body comprises a composite material including a plurality of relatively higher-modulus reinforcement elements, a plurality of relatively tougher polymer-based reinforcement elements, and a matrix material substantially encapsulating the plurality of relatively higher-modulus reinforcement elements and the plurality of relatively tougher polymer-based reinforcement elements, wherein the plurality of relatively higher-modulus reinforcement elements are different from the plurality of relatively tougher polymer-based reinforcement elements, wherein the side wall comprises a plurality of annular regions arranged from the forward side of the body to the aft side of the body, wherein each respective annular region comprises a plurality of layers having a respective ratio of relatively higher-modulus reinforcement elements to relatively tougher polymer-based reinforcement elements, and wherein the respective ratio of each forward annular region is greater than the respective ratio of an adjacent aft annular region.