Ceramic matrix composite turbine nozzle shell and method of assembly

A method of manufacturing a ceramic matrix composite (CMC) turbine nozzle shell, the method comprising:

• stacking and de-bulking a first plurality of platform plies to assemble a primary outer nozzle platform;
• stacking and de-bulking a second plurality of platform plies to assemble a primary inner nozzle platform;
• stacking a plurality of trailing edge plies in a V-shape;
• assembling a core and trailing edge preform by wrapping a plurality of core plies around a tool having a wider end and a narrower end to define a hollow airfoil shape and by arranging the stacked trailing edge plies adjacent the narrower end of the plurality of core plies;
• assembling an airfoil-shaped body by:
• circumferentially wrapping a set of composite wrap plies around the core and trailing edge preform, each composite wrap ply of the set of composite wrap plies having a first layer with first unidirectional fibers oriented in parallel to a longitudinal axis of the CMC turbine nozzle shell and a second layer having unidirectional fibers oriented in a transverse direction relative to the first unidirectional fibers, wherein each composite wrap ply has a first longitudinal edge and a second longitudinal edge;
• cutting the first longitudinal edge and the second longitudinal edge into fingers;
• and
• folding the fingers in a transverse direction away from the core plies and interleaving the fingers of each composite wrap ply between secondary platform plies to define a secondary inner nozzle platform and a secondary outer nozzle platform;
• joining the primary outer nozzle platform to the secondary outer nozzle platform;
• and
• joining the primary inner nozzle platform to the secondary inner nozzle platform,
• wherein:
• the primary outer nozzle platform includes a plurality of stacked primary platform plies at least three in number directly adjacent to one another which are disposed axially outward from the composite wrap plies defining the airfoil shape;
• the primary inner nozzle platform includes a plurality of stacked primary platform plies at least three in number directly adjacent to one another which are disposed axially inward from the composite wrap plies defining the airfoil shape;
• or
• the primary outer nozzle platform includes a plurality of stacked primary platform plies at least three in number directly adjacent to one another which are disposed axially outward from the composite wrap plies defining the airfoil shape and the primary inner nozzle platform includes a plurality of stacked primary platform plies at least three in number directly adjacent to one another which are disposed axially inward from the composite wrap plies defining the airfoil shape.