# US 2020/0400027 A1 · Composite blade and method for molding composite blade

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- Number: US 2020/0400027 A1
- Document ID: US20200400027A1
- Status: Published application
- Kind: A1
- Application number: 16/790,903
- Filed: 2020-02-14
- Published: 2020-12-24
- Earliest claimed: 2019-06-19
- Assignees: Mitsubishi Heavy Industries, Ltd.
- Applicants: Mitsubishi Heavy Industries, Ltd.
- Inventors: Ryoji OKABE; Masami Kamiya; Kentaro SHINDO
- Web page: https://patentgrep.com/patent/US20200400027A1

## CPC

- F01D 5/282: {Selecting composite materials, e.g. blades with reinforcing filaments}
- B29C 70/222: {the structure being shaped to form a three dimensional configuration}
- B29C 70/302: {Details of the edges of fibre composites, e.g. edge finishing or means to avoid delamination}
- B29C 70/345: {using matched moulds}
- B29C 70/86: Incorporated in coherent impregnated reinforcing layers, {e.g. by winding}
- B29D 99/0025: {Producing blades or the like, e.g. blades for turbines, propellers, or wings}
- F01D 5/3007: {of axial insertion type}
- F01D 5/3092: {Protective layers between blade root and rotor disc surfaces, e.g. anti-friction layers (F01D5/288 takes precedence)}
- B29L 2031/08: Blades for rotors, stators, fans, turbines or the like, e.g. screw propellers
- F05D 2230/23: by permanently joining parts together
- F05D 2240/80: Platforms for stationary or moving blades
- F05D 2300/50211: similar
- F05D 2300/603: Composites; e.g. fibre-reinforced
- F05D 2300/6034: Orientation of fibres, weaving, ply angle
- Y02T 50/60: Efficient propulsion technologies, e.g. for aircraft
- F01D: NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES (machines or engines for liquids F03; non-positive displacement pumps F04D)
- 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)
- B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00)
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- F05D: INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION

## Abstract

A composite blade formed by laying up composite layers containing reinforcing fiber and resin, the composite blade comprising: a blade root mounted in a blade groove; an airfoil extending from the blade root to a front end side; and a metal patch mounted between the blade groove and the blade root, and bonded to the blade root.

## Claims

### Claim 1

A composite blade formed by laying up composite layers containing reinforcing fiber and resin, the composite blade comprising:
a blade root mounted in a blade groove;
an airfoil extending from the blade root to a front end side; and
a metal patch mounted between the blade groove and the blade root, and bonded to the blade root, wherein
the blade root is a laminate with the laid-up composite layers and includes
an airfoil laminate continuous from the airfoil,
a blade root inner laminate mounted on the inner side of the airfoil laminate, and
a blade root outer laminate mounted on the outer side of the airfoil laminate, and
the reinforcing fiber is oriented in the blade root inner laminate and the blade root outer laminate so that a linear expansion coefficient of the blade root is approximate to a linear expansion coefficient of the metal patch.

### Claim 2 (depends on 1)

The composite blade according to claim 1, wherein
when a direction in which the airfoil extends is defined as a 0° direction, orientation ratios of the reinforcing fiber oriented in ±45° directions in the blade root inner laminate and the blade root outer laminate are higher than 30% and lower than 60%.

### Claim 3 (depends on 2)

The composite blade according to claim 2, wherein
the orientation ratios of the reinforcing fiber oriented in the ±45° directions in the blade root inner laminate and the blade root outer laminate are equal to or higher than 35% and equal to or lower than 55%.

### Claim 4 (depends on 3)

The composite blade according to claim 3, wherein
orientation ratios of the reinforcing fiber oriented in the 0° direction in the blade root inner laminate and the blade root outer laminate are equal to or higher than 45% and equal to or lower than 65% and are the remaining orientation ratios of the orientation ratios of the reinforcing fiber oriented in the ±45° directions.

### Claim 5 (depends on 3)

The composite blade according to claim 3, wherein
the orientation ratios of the reinforcing fiber oriented in the ±45° directions in the blade root inner laminate and the blade root outer laminate are equal to or higher than 44% and equal to or lower than 55%.

### Claim 6 (depends on 1)

The composite blade according to claim 1, wherein
a curved section exists between the blade root and the air foil, and
the metal patch is mounted on only the blade root.

### Claim 7 (depends on 1)

The composite blade according to claim 1, wherein
the blade root includes a dent on which the metal patch is mounted.

### Claim 8 (depends on 1)

The composite blade according to claim 1, wherein
when a direction extending from the side of the blade root to the front end side is defined as a length direction and a direction perpendicular to the length direction is defined as a width direction in a mounting surface of the blade root on which the metal patch is mounted, the metal patch includes cuts formed at predetermined intervals in the width direction.

### Claim 9

A method for molding a composite blade formed by laying up composite layers containing reinforcing fiber and resin, wherein
the composite blade includes
a blade root mounted in a blade groove,
an airfoil extending from the blade root to a front end side, and
a metal patch mounted between the blade groove and the blade root and bonded to the blade root, and
the blade root is a laminate with the laid-up composite layers and includes
an airfoil laminate continuous from the airfoil,
a blade root inner laminate mounted on the inner side of the airfoil laminate, and
a blade root outer laminate mounted on the outer side of the airfoil laminate,
the method comprises:
a set process of placing the metal patch on a forming mold for molding the blade root;
a laying-up process of laying up the composite layers on the metal patch and forming the airfoil laminate, the blade root inner laminate, and the blade root outer laminate; and
a hardening process of heating and hardening the airfoil laminate, the blade root inner laminate, and the blade root outer laminate, and
at the laying-up process, the reinforcing fiber is oriented in the blade root inner laminate and the blade root outer laminate so that a linear expansion coefficient of the blade root is approximate to a linear expansion coefficient of the metal patch.