Composite air foil and disc assembly

Claim 2

For use in a turbomachine, an integral composite airfoil and disc assembly adapted for rotation about an axis said assembly including a radially outer airfoil portion having a plurality of generally radially and axially extending circumferentially spaced-apart airfoils and a bore portion disposed radially inward of said airfoil portion, the invention comprising: a first plurality of filamented plies comprising said airfoil portion and said bore portion, said plies including a plurality of first filaments comprising one of said airfoils and disposed generally parallel to a radial line emanating perpendicularly from said axis, said plies disposed axially adjacent each other in said airfoil portion, at least two adjacent plies splaying in said bore portion axially away from each other providing in said bore portion an axial gap between said splayed apart adjacent plies; a second plurality of filamented plies disposed in said gap, said second plurality of plies including a second filament oriented to extend generally in a direction circumferential about said axis, and wherein said axial gap between said adjacent plies increases in axial width in the radially inward direction and said second plurality of plies has axial cross-sectional width which increases in the radially inward direction; and a matrix material interspersed between said first plurality of filament plies and said second filament.

Claim 3

For use in a turbomachine, an integral composite airfoil and disc assembly adapted for rotation about an axis said assembly including a radially outer airfoil portion having a plurality of generally radially and axially extending circumferentially spaced-apart airfoils and a bore portion disposed radially inward of said airfoil portion, the invention comprising: a first plurality of filamented plies comprising said airfoil portion and said bore portion, said plies including a plurality of first filaments comprising one of said airfoils and disposed generally parallel to a radial line emanating perpendicularly from said axis, said plies disposed axially adjacent each other in said airfoil portion, at least two adjacent plies splaying in said bore portion axially away from each other providing in said bore portion a gap between said splayed apart adjacent plies; a second plurality of filamented plies disposed in said gap, said second plurality of plies including a second filament oriented to extend generally in a direction circumferential about said axis; a matrix material interspersed between said first plurality of filament plies and said second filament; and wherein each of said airfoils is comprised of each of said plies in said first plurality of plies and said plurality of first filaments in one of said plies is disposed at an angle with said first filaments in other of said plies, said angle being essentially equal to a whole number multiple of 360° divided by the number of airfoils in said airfoil portion.

Claim 4

For use in a turbomachine, an integral composite airfoil and disc assembly adapted for rotation about an axis said assembly including a radially outer airfoil portion having a plurality of generally radially and axially extending circumferentially spaced-apart airfoils and a bore portion disposed radially inward of said airfoil portion, the invention comprising: a first plurality of filamented plies comprising said airfoil portion and said bore portion, said plies including a plurality of first filaments comprising one of said airfoils and disposed generally parallel to a radial line emanating perpendicularly from said axis, said plies disposed axially adjacent each other in said airfoil portion, at least two adjacent plies splaying in said bore portion axially away from each other providing in said bore portion a gap between said splayed apart adjacent plies; a second plurality of filamented plies disposed in said gap, said second plurality of plies including a second filament oriented to extend generally in a direction circumferential about said axis; a matrix material interspersed between said first plurality of filament plies and said second filament; and wherein each of said airfoils is comprised of each of said plies in said first plurality of plies and said plurality of first filaments in one of said plies is disposed at an angle with said first filaments in other of said plies, said angle being essentially equal to a whole number multiple of 360° divided by the number of airfoils in said airfoil portion.

Claim 5

For use in a turbomachine, an integral composite airfoil and disc assembly adapted for rotation about an axis said assembly including a radially outer airfoil portion having a plurality of generally radially and axially extending circumferentially spaced-apart airfoils and a bore portion disposed radially inward of said airfoil portion, the invention comprising: a first plurality of filamented plies comprising said airfoil portion and said bore portion, said plies including a plurality of first filaments comprising one of said airfoils and disposed generally parallel to a radial line emanating perpendicularly from said axis, said plies disposed axially adjacent each other in said airfoil portion, at least two adjacent plies splaying in said bore portion axially away from each other providing in said bore portion a gap between said splayed apart adjacent plies; a second plurality of filamented plies disposed in said gap, said second plurality of plies including a second filament oriented to extend generally in a direction circumferential about said axis; a matrix material interspersed between said first plurality of filament plies and said second filament; and means for applying an axial clamping load to said assembly proximate said bore portion.

Claim 6

For use in a turbomachine, an integral composite airfoil and disc assembly adapted for rotation about an axis said assembly including a radially outer airfoil portion having a plurality of generally radially and axially extending circumferentially spaced-apart airfoils and a bore portion disposed radially inward of said airfoil portion, the invention comprising: a first plurality of filamented plies comprising said airfoil portion and said bore portion, said plies including a plurality of first filaments comprising one of said airfoils and disposed generally parallel to a radial line emanating perpendicularly from said axis, said plies disposed axially adjacent each other in said airfoil portion, at least two adjacent plies splaying in said bore portion axially away from each other providing in said bore portion a gap between said splayed apart adjacent plies; a second plurality of filamented plies disposed in said gap, said second plurality of plies including a second filament oriented to extend generally in a direction circumferential about said axis; a matrix material interspersed between said first plurality of filament plies and said second filament; and means for applying an axial clamping load to said assembly proximate said bore portion.

Claim 7

For use in turbo machinery having an integral composite airfoil and disc assembly adapted for rotation about an axis, said assembly including a radially outer airfoil portion having a plurality of generally radially and axially extending circumferentially spaced-apart airfoils and a bore portion disposed radially inward of said airfoil portion, the invention comprising: a first plurality of filamented plies comprising said airfoil portion and said bore portion, each of said plies including a plurality of first filaments comprising a portion of one of said airfoils dispersed generally parallel to a radial line emanating perpendicularly from said axis, said plies disposed axially adjacent each other in said airfoil portion; a plurality of axially spaced-apart annular gaps disposed in said bore portion between said plies of said first plurality; a plurality of annular inserts, each insert including a second plurality of filamented plies comprising said bore portion, each of said inserts disposed in one of said gaps, each of said plies in said second plurality including a plurality of second filaments extending circumferentially about said axis; a matrix material interspersed between said first filaments and said second filaments; and wherein said gaps between said plies are comprised of a cross-section having a wedge-shaped configuration and said inserts are comprised of a cross-section having a wedge-shaped configuration.

Claim 8

For use in turbo machinery having an integral composite airfoil and disc assembly adapted for rotation about an axis, said assembly including a radially outer airfoil portion having a plurality of generally radially and axially extending circumferentially spaced-apart airfoils and a bore portion disposed radially inward of said airfoil portion, the invention comprising: a first plurality of filamented plies comprising said airfoil portion and said bore portion, each of said plies including a plurality of first filaments comprising a portion of one of said airfoils dispersed generally parallel to a radial line emanating perpendicularly from said axis, said plies disposed axially adjacent each other in said airfoil portion; a plurality of axially spaced-apart annular gaps disposed in said bore portion between said plies of said first plurality; a plurality of annular inserts, each insert including a second plurality of filamented plies comprising said bore portion, each of said inserts disposed in one of said gaps, each of said plies in said second plurality including a plurality of second filaments extending circumferentially about said axis; a matrix material interspersed between said first filaments and said second filaments; and wherein said gaps between said plies are comprised of a cross-section having a wedge-shaped configuration and said inserts are comprised of a cross-section having a wedge-shaped configuration.

Claim 9

For use in turbo machinery having an integral composite airfoil and disc assembly adapted for rotation about an axis, said assembly including a radially outer airfoil portion having a plurality of generally radially and axially extending circumferentially spaced-apart airfoils and a bore portion disposed radially inward of said airfoil portion, the invention comprising: a first plurality of filamented plies comprising said airfoil portion and said bore portion, each of said plies including a plurality of first filaments comprising a portion of one of said airfoils disposed generally parallel to a radial line emanating perpendicularly from said axis, said plies disposed axially adjacent each other in said airfoil portion; a plurality of axially spaced-apart annular gaps disposed in said bore portion between said plies of said first plurality; a plurality of annular inserts, each insert including a second plurality of filamented plies comprising said bore portion, each of said inserts disposed in one of said gaps, each of said plies in said second plurality including a plurality of second filaments extending circumferentially about said axis; a matrix material interspersed between said first filaments and said second filaments; and wherein each of said airfoils is comprised of each of said plies in said first plurality of plies and said plurality of first filaments in one of said plies is disposed at an angle with said first filaments in other of said plies, said angle being essentially equal to a whole number multiple of 360° divided by the number of airfoils in said airfoil portion.

Claim 10

For use in turbo machinery having an integral composite airfoil and disc assembly adapted for rotation about an axis, said assembly including a radially outer airfoil portion having a plurality of generally radially and axially extending circumferentially spaced-apart airfoils and a bore portion disposed radially inward of said airfoil portion, the invention comprising: a first plurality of filamented plies comprising said airfoil portion and said bore portion, each of said plies including a plurality of first filaments comprising a portion of one of said airfoils disposed generally parallel to a radial line emanating perpendicularly from said axis, said plies disposed axially adjacent each other in said airfoil portion; a plurality of axially spaced-apart annular gaps disposed in said bore portion between said plies of said first plurality; a plurality of annular inserts, each insert including a second plurality of filamented plies comprising said bore portion, each of said inserts disposed in one of said gaps, each of said plies in said second plurality including a plurality of second filaments extending circumferentially about said axis; a matrix material interspersed between said first filaments and said second filaments; and wherein each of said airfoils is comprised of each of said plies in said first plurality of plies and said plurality of first filaments in one of said plies is disposed at an angle with said first filaments in other of said plies, said angle being essentially equal to a whole number multiple of 360° divided by the number of airfoils in said airfoil portion.

Claim 11

For use in turbo machinery having an integral composite airfoil and disc assembly adapted for rotation about an axis, said assembly including a radially outer airfoil portion having a plurality of generally radially and axially extending circumferentially spaced-apart airfoils and a bore portion disposed radially inward of said airfoil portion, the invention comprising: a first plurality of filamented plies comprising said airfoil portion and said bore portion, each of said plies including a plurality of first filaments comprising a portion of one of said airfoils disposed generally parallel to a radial line emanating perpendicularly from said axis, said plies disposed axially adjacent each other in said airfoil portion; a plurality of axially spaced-apart annular gaps disposed in said bore portion between said plies of said first plurality; a plurality of annular inserts, each insert including a second plurality of filamented plies comprising said bore portion, each of said inserts disposed in one of said gaps, each of said plies in said second plurality including a plurality of second filaments extending circumferentially about said axis; a matrix material interspersed between said first filaments and said second filaments; and means for applying an axial clamping load to said assembly proximate said bore portion.

Claim 12

For use in turbo machinery having an integral composite airfoil and disc assembly adapted for rotation about an axis, said assembly including a radially outer airfoil portion having a plurality of generally radially and axially extending circumferentially spaced-apart airfoils and a bore portion disposed radially inward of said airfoil portion, the invention comprising: a first plurality of filamented plies comprising said airfoil portion and said bore portion, each of said plies including a plurality of first filaments comprising a portion of one of said airfoils disposed generally parallel to a radial line emanating perpendicularly from said axis, said plies disposed axially adjacent each other in said airfoil portion; a plurality of axially spaced-apart annular gaps disposed in said bore portion between said plies of said first plurality; a plurality of annular inserts, each insert including a second plurality of filamented plies comprising said bore portion, each of said inserts disposed in one of said gaps, each of said plies in said second plurality including a plurality of second filaments extending circumferentially about said axis; a matrix material interspersed between said first filaments and said second filaments; and means for applying an axial clamping load to said assembly proximate said bore portion.