US 12,391,010 B2
Methods of manufacture for composite blades
George Alan Salisbury, East Hampton, CT (US); and Royce E. Tatton, Shelley, ID (US)
Assigned to RTX Corporation, Farmington, CT (US)
Filed by Raytheon Technologies Corporation, Farmington, CT (US)
Filed on Jan. 13, 2023, as Appl. No. 18/097,142.
Prior Publication US 2024/0239057 A1, Jul. 18, 2024
Int. Cl. B29C 70/38 (2006.01); B29C 70/34 (2006.01); B29C 70/44 (2006.01); B29C 70/54 (2006.01); B29K 105/08 (2006.01); B29L 31/08 (2006.01); F01D 5/28 (2006.01)
CPC B29C 70/382 (2013.01) [B29C 70/44 (2013.01); B29C 70/545 (2013.01); B29K 2105/0872 (2013.01); B29L 2031/082 (2013.01); F01D 5/282 (2013.01); F05D 2230/20 (2013.01); F05D 2300/603 (2013.01)] 17 Claims
OG exemplary drawing
 
1. A method of manufacturing composite gas turbine engine blades, the method comprising:
laying up a pre-impregnated composite material to form a continuous pre-impregnated composite structure, the continuous pre-impregnated composite structure comprising a first pre-impregnated composite gas turbine engine blade and a second pre-impregnated composite gas turbine engine blade, the first pre-impregnated composite gas turbine engine blade extending outward from an overlap portion to a first tip and defining a first pressure side and a first suction side, the second pre-impregnated composite gas turbine engine blade extending outward from the overlap portion to a second tip and defining a second pressure side and a second suction side;
vacuum bagging the continuous pre-impregnated composite structure between a first pressure plate and a second pressure plate, the first pressure plate interfacing with the first pressure side of the first pre-impregnated composite gas turbine engine blade and the second suction side of the second pre-impregnated composite gas turbine engine blade, the second pressure plate interfacing with the second pressure side of the second pre-impregnated composite gas turbine engine blade and the first suction side of the first pre-impregnated composite gas turbine engine blade;
consolidating then curing the continuous pre-impregnated composite structure to form a fiber-reinforced composite structure; and
machining the overlap portion of the fiber-reinforced composite structure to form a first fiber-reinforced composite gas turbine engine blade and a second fiber-reinforced composite gas turbine engine blade.