Functionally graded composite fan containment case

Abstract

A fan containment case for a gas turbine engine includes a first inner layer and a second layer outside the first inner layer, where the second layer is made of a first material having a first fabric architecture. The fan containment case also includes a third layer outside of the second layer, where the third layer is made of a second material having a second fabric architecture, and at least one of the first material and the first fabric architecture of the second layer is different from the second material and the second architecture, respectively, of the third layer. A fourth outer layer is located outside of the third layer.

What is claimed is: 
     
         1 . A fan containment case for a gas turbine engine comprising:
 a first inner layer;   a second layer outside the first inner layer, wherein the second layer is made of a first material having a first fabric architecture;   a third layer outside of the second layer, wherein the third layer is made of a second material having a second fabric architecture, wherein at least one of the first material and the first fabric architecture of the second layer is different from the second material and the second architecture, respectively, of the third layer; and   a fourth outer layer outside of the third layer.   
     
     
         2 . The fan containment case as recited in  claim 1 , wherein the first inner layer is an aramid fiber layer. 
     
     
         3 . The fan containment case as recited in  claim 1 , wherein the first inner layer has a fabric architecture of a three dimensional weave. 
     
     
         4 . The fan containment case as recited in  claim 1 , wherein the first material of the second layer is a hybrid carbon-fiberglass. 
     
     
         5 . The fan containment case as recited in  claim 1 , wherein the first architecture of the second layer is a triaxial braid. 
     
     
         6 . The fan containment case as recited in  claim 5 , wherein the triaxial braid includes first fibers, second fibers and third fibers, and the second fibers and third fibers extend at a weave angle of about +/−60° relative to the first fibers. 
     
     
         7 . The fan containment case as recited in  claim 6 , wherein the first fibers are carbon fibers, and the second fibers and the third fibers are fiberglass fibers. 
     
     
         8 . The fan containment case as recited in  claim 1 , wherein the second material of the third layer is carbon. 
     
     
         9 . The fan containment case as recited in  claim 1 , wherein the second architecture of the third layer is a triaxial braid. 
     
     
         10 . The fan containment case as recited in  claim 9 , wherein the triaxial braid includes first fibers, second fibers and third fibers, and the second fibers and third fibers extend at a weave angle of about +/−45° relative to the first fibers. 
     
     
         11 . The fan containment case as recited in  claim 10 , wherein the first fibers, the second fibers and the third fibers are carbon fibers. 
     
     
         12 . The fan containment case as recited in  claim 1 , wherein the fourth outer layer is made of carbon. 
     
     
         13 . The fan containment case as recited in  claim 1 , wherein the fourth outer layer has a fabric architecture of a non-crimp fabric. 
     
     
         14 . A fan containment case for a gas turbine engine comprising:
 a first inner layer of an aramid fiber;   a second layer outside the first inner layer, wherein the second layer is made of a hybrid carbon-fiberglass having a first fabric architecture;   a third layer outside of the second layer, wherein the third layer is made of carbon and has second fabric architecture, and the first fabric architecture is different from the second architecture; and   a fourth outer layer outside of the third layer, wherein the fourth outer layer is made of carbon.   
     
     
         15 . The fan containment case as recited in  claim 14 , wherein the first architecture of the second layer is a triaxial braid including first fibers, second fibers and third fibers, and the second fibers and third fibers extend at a weave angle of about +/−60° relative to the first fibers. 
     
     
         16 . The fan containment case as recited in  claim 15 , wherein the first fibers are carbon fibers, and the second fibers and the third fibers are fiberglass fibers. 
     
     
         17 . The fan containment case as recited in  claim 14 , wherein the second architecture of the second layer is a triaxial braid including first fibers, second fibers and third fibers, and the second fibers and third fibers extend at a weave angle of about +/−45° relative to the first fibers. 
     
     
         18 . The fan containment case as recited in  claim 17 , wherein the first fibers, the second fibers and the third fibers are carbon fibers. 
     
     
         19 . The fan containment case as recited in  claim 14 , wherein the first inner layer has a fabric architecture of a three dimensional weave. 
     
     
         20 . The fan containment case as recited in  claim 14 , wherein the fourth outer layer has a fabric architecture of a non-crimp fabric.