# US 2013/0153456 A1 · Containment case and method of manufacture

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- Number: US 2013/0153456 A1
- Document ID: US20130153456A1
- Status: Published application
- Kind: A1
- Application number: 13/326,455
- Filed: 2011-12-15
- Published: 2013-06-20
- Earliest claimed: 2011-12-15
- Assignees: General Electric Company
- Inventors: Qi Zhu; Scott Roger Finn
- Web page: https://patentgrep.com/patent/US20130153456A1

## CPC

- 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
- F01D 5/28: Selecting particular materials; {Particular measures relating thereto;} Measures against erosion or corrosion
- F01D 5/282: {Selecting composite materials, e.g. blades with reinforcing filaments}
- F01D 25/24: Casings (modified for heating or cooling F01D25/14); Casing parts, e.g. diaphragms, casing fastenings (casings for rotary machines or engines in general F16M {; special arrangements in stators dealing with breaking-off of part of rotor F01D21/045})
- B29K 2995/0089: Impact strength or toughness
- B29L 2031/7504: {Turbines}
- Y02T 50/60: Efficient propulsion technologies, e.g. for aircraft
- 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)
- F01D: NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES (machines or engines for liquids F03; non-positive displacement pumps F04D)
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION

## Abstract

A containment case comprises a composite core, with an inner and outer surface, at least one puncture resistant layer bonded to the inner surface of the composite core and at least one energy capture layer bonded to the outer surface of the composite core. The puncture resistant layer having a high through-thickness shear strength and high interlaminar toughness at impact. The energy capture layer having a high in-plane tensile strength and low resistance to delamination and fiber-matrix debonding at impact. A method of fabricating a containment case includes the steps of disposing one or more layers of a puncture resistant material on a layup mandrel, disposing one more layers of a structural composite material on an exterior surface of the puncture resistant material, disposing one or more layers of an energy capture material on an exterior surface of the structural material and curing a resin in the plurality of layers.

## Claims

### Claim 1

A containment case comprising:
a composite core having an inner surface and an outer surface;
at least one puncture resistant layer integrated with the composite core, wherein the at least one puncture resistant layer includes a resin to bond the at least one puncture resistant layer to the inner surface of the composite core; and
at least one energy capture layer integrated with the composite core, wherein the at least one energy capture layer includes a resin to bond the at least one energy capture layer to the outer surface of the composite core.

### Claim 2 (depends on 1)

The containment case of claim 1, wherein the at least one puncture resistant layer comprises a fiber and resin material with high through-thickness shear strength and high interlaminar toughness at impact.

### Claim 3 (depends on 2)

The containment case of claim 2, wherein the at least one puncture resistant layer comprises at least one of a nonwoven fabric, a wrap, a blanket, a winding, a woven fabric, a knitted fabric, a carded non-woven fabric, or a braided fabric.

### Claim 4 (depends on 3)

The containment case of claim 3, wherein the at least one puncture resistant layer comprises fibers comprised of at least one of S2 glass, E-glass, quartz, alumina, silica, boron oxide, or carbon and a resin with high fracture toughness.

### Claim 5 (depends on 4)

The containment case of claim 4, wherein the at least one puncture resistant layer comprises S2 glass fibers and a dicyclopentadiene (DCPD) resin.

### Claim 6 (depends on 1)

The containment case of claim 1, wherein the at least one energy capture layer comprises a fiber and resin material with high in-plane tensile strength and low resistance to delamination and fiber-matrix debonding.

### Claim 7 (depends on 6)

The containment case of claim 6, wherein the at least one energy capture layer comprises at least one of a nonwoven fabric, a wrap, a blanket, a winding, a woven fabric, a knitted fabric, a carded non-woven fabric, or a braided fabric.

### Claim 8 (depends on 7)

The containment case of claim 7, wherein the at least one energy capture layer comprises fibers comprised of at least one of graphite, carbon, polyimide, aromatic polyamide, or ultra-high molecular weight polyethylene and a resin that does not bond well with the fibers to facilitate delamination and fiber-matrix debonding.

### Claim 9 (depends on 8)

The containment case of claim 8, wherein the at least one energy capture layer further comprises at least one of a fiber sizing or surface treatment for minimizing fiber-to-resin adhesion.

### Claim 10 (depends on 8)

The containment case of claim 8, wherein the at least one energy capture layer comprises carbon fibers and a dicyclopentadiene (DCPD) resin.

### Claim 11 (depends on 1)

The containment case of claim 1, wherein the at least one puncture resistant layer comprises S2 glass fibers and a dicyclopentadiene (DCPD) resin and the at least one energy capture layer comprises carbon fibers and a dicyclopentadiene (DCPD) resin.

### Claim 12 (depends on 1)

The containment case of claim 1, wherein the composite core comprises a reinforcing fabric.

### Claim 13 (depends on 12)

The containment case of claim 12, wherein the composite core further includes reinforcement stitching to control delamination upon impact.

### Claim 14

A containment case comprising:
a composite core with an inner surface and an outer surface;
at least one puncture resistant layer disposed in a primary impact zone and integrated with the composite core, wherein the at least one puncture resistant layer is configured coextensive with a length of the composite core and includes a resin to bond the at least one puncture resistant layer to the inner surface of the composite core, the at least one puncture resistant layer characterized by a high through-thickness shear strength and a high interlaminar toughness at impact; and
at least one energy capture layer disposed in a primary impact zone and integrated with the composite core, wherein the at least one energy capture layer is configured coextensive with a length of the composite core and includes a resin to bond the at least one energy capture layer to the outer surface of the composite core, the at least one energy capture layer characterized by a high in-plane tensile strength and low resistance to delamination and fiber-matrix debonding at impact.

### Claim 15 (depends on 14)

The containment case of claim 14, wherein the at least one puncture resistant layer comprises fibers comprised of S2 glass, E-glass, quartz, alumina, silica, boron oxide, or carbon fibers and a resin with high fracture toughness.

### Claim 16 (depends on 15)

The containment case of claim 15, wherein the at least one puncture resistant layer comprises S2 glass fibers and a dicyclopentadiene (DCPD) resin.

### Claim 17 (depends on 14)

The containment case of claim 14, wherein the at least one energy capture layer comprises fibers comprised of at least one of graphite, carbon, polyimide, aromatic polyamide, or ultra-high molecular weight polyethylene and a resin that does not bond well with the fibers to facilitate delamination and fiber-matrix debonding.

### Claim 18 (depends on 17)

The containment case of claim 17, wherein the at least one energy capture layer comprises carbon fibers and a dicyclopentadiene (DCPD) resin.

### Claim 19 (depends on 14)

The containment case of claim 14, wherein the at least one puncture resistant layer comprises S2 glass fibers and a dicyclopentadiene (DCPD) resin and the at least one energy capture layer comprises carbon fibers and a dicyclopentadiene (DCPD) resin.

### Claim 20

A method of fabricating a containment case, the method comprising:
disposing one or more layers of a puncture resistant material on a layup mandrel;
disposing one more layers of a structural composite material on an exterior surface of the puncture resistant material;
disposing one or more layers of an energy capture material on an exterior surface of the structural material; and
curing a resin in the composite core, the one or more layers of the puncture resistant material and the one or more layers of the energy capture material.

### Claim 21 (depends on 20)

The method of claim 20, further comprising infusing the composite core, the one or more layers of the puncture resistant material and the one or more layers of the energy capture material with resin.

### Claim 22 (depends on 20)

The method of claim 20, wherein the one or more layers of the puncture resistant material comprises fibers comprised of S2 glass, E-glass, quartz, alumina, silica, boron oxide, or carbon fibers and a resin with high fracture toughness.

### Claim 23 (depends on 19)

The method of claim 19, wherein the one or more layers of the energy capture material comprises fibers comprised of at least one of graphite, carbon, polyimide, aromatic polyamide, or ultra-high molecular weight polyethylene and a resin that does not bond well with the fibers to facilitate delamination and fiber-matrix debonding.

### Claim 24 (depends on 19)

The method of claim 19, further including a step of at least partially curing a resin in the composite core and the one or more layers of the puncture resistant material, prior to disposing one or more layers of an energy capture material on an exterior surface of the structural material.