Hybrid Continuous Fiber Chopped Fiber Polymer Composite Structure

Abstract

An engine component having a monolithic composite body, the body having a continuous fiber portion, a chopped fiber portion, a thermoplastic polymer contained in both the continuous fiber portion and the chopped fiber portion and between the continuous and chopped fiber portions.

What is claimed is: 
     
         1 . An aircraft engine component, comprising:
 a monolithic composite body;   said body having:
 a continuous fiber portion; 
 a chopped fiber portion; 
 a thermoplastic polymer contained in both said continuous fiber portion and said chopped fiber portion and between said continuous and chopped fiber portions. 
   
     
     
         2 . The aircraft engine component of  claim 1 , wherein said thermoplastic polymer is one of PEEK, PPS, PEKK, and PEI. 
     
     
         3 . The aircraft engine component of  claim 1 , wherein the fiber is one of carbon fiber, glass fiber and a mixture of said carbon fiber and said glass fiber. 
     
     
         4 . The aircraft engine component of  claim 1 , wherein said continuous fiber is one a braid, woven fiber and a unidirectional tape. 
     
     
         5 . The aircraft engine component of  claim 1 , wherein said chopped fiber constituent is formed of a unidirectional preimpregnated tape. 
     
     
         6 . The aircraft engine component of  claim 5 , wherein said chopped fiber length is less than one inch (1″). 
     
     
         7 . The aircraft engine component of  claim 1  further comprising one or more co-molded metallic features. 
     
     
         8 . The aircraft engine component of  claim 7 , said co-molded metallic features being one of a flange, bushing and threaded insert. 
     
     
         9 . The aircraft engine component of  claim 1 , said continuous fiber of said composite body carrying a hoop load. 
     
     
         10 . The aircraft engine component of  claim 1 , wherein said continuous fiber is a braided preform that contains at least one of fibers of carbon, glass and thermoplastic. 
     
     
         11 . The aircraft engine component of  claim 10  wherein said at least one of fibers is dry carbon fiber and thermoplastic fiber. 
     
     
         12 . The aircraft engine component of  claim 10  wherein said at least one of fibers is dry carbon fiber, glass fiber and thermoplastic fiber. 
     
     
         13 . The aircraft engine component of  claim 1 , wherein said chopped fiber portion fails to carry a structural load. 
     
     
         14 . The aircraft engine component of  claim 1 , wherein said chopped fiber portion is adjacent to an engine air flowpath. 
     
     
         15 . The aircraft engine component of  claim 14  further comprising an erosion protection layer on an outermost surface of said chopped fiber portion. 
     
     
         16 . The aircraft engine component of  claim 1 , said component being a rotating part. 
     
     
         17 . The aircraft engine component of  claim 16 , said rotating part being a spinner nose cone. 
     
     
         18 . The aircraft engine component of  claim 16 , said rotating part being a spinner support ring.