Monolithic Composite Blade and Platform

Abstract

A component for a gas turbine engine. The component includes a continuous fiber blade including an airfoil extending radially between a root and a tip and a blade attachment feature positioned at or adjacent to the root. The component further includes a platform coupled to the root of the continuous fiber blade. The platform includes a plurality of chopped fibers. Additionally, the component includes a thermoplastic polymer contained in both the continuous fiber blade and the platform. Moreover, the continuous fiber blade and platform are coupled together such that the continuous fiber blade and platform form a monolithic composite body.

What is claimed is: 
     
         1 . A component for a gas turbine engine, the component comprising:
 a continuous fiber blade including an airfoil extending radially between a root and a tip and a blade attachment feature positioned at or adjacent to the root;   a platform coupled to the root of the continuous fiber blade, the platform including a plurality of chopped fibers; and   a thermoplastic polymer contained in both the continuous fiber blade and the platform,   wherein the continuous fiber blade and platform are coupled together such that the continuous fiber blade and platform form a monolithic composite body.   
     
     
         2 . The component of  claim 1 , wherein the continuous fiber blade is formed, at least in part, by molding of a continuous fiber thermoplastic composite. 
     
     
         3 . The component of  claim 1 , wherein the platform is formed, at least in part, by at least one of compression molding or injection molding of the plurality of chopped fibers. 
     
     
         4 . The component of  claim 3 , wherein the platform is coupled to the continuous fiber blade via injection molding at an interface between the platform and the continuous fiber blade. 
     
     
         5 . The component of  claim 3 , wherein the platform is coupled to the continuous fiber blade simultaneously with the molding of the platform. 
     
     
         6 . The component of  claim 1 , wherein the thermoplastic polymer includes a bonding layer between the continuous fiber blade and the platform. 
     
     
         7 . The component of  claim 1 , wherein the continuous fiber blade defines a pressure side and a suction side, and wherein the platform is coupled to the pressure side or suction side of the continuous fiber blade. 
     
     
         8 . The component of  claim 1 , wherein the continuous fiber blade defines a pressure side and a suction side, and wherein the platform comprises two platforms, a first platform coupled to the pressure side of the continuous fiber blade, and a second platform coupled to the suction side of the continuous fiber blade. 
     
     
         9 . The component of  claim 1 , wherein the platform comprises a split platform defining a notch such that the continuous fiber blade is received within the notch and coupled to the split platform at the notch. 
     
     
         10 . The component of  claim 1 , wherein the thermoplastic polymer comprises at least one of PEKK, PEEK, PAEK, or PEI. 
     
     
         11 . A gas turbine engine defining a centerline, the gas turbine engine comprising:
 an engine shaft extending along the centerline;   a compressor attached to the engine shaft and extending radially about the centerline;   a combustor positioned downstream of the compressor to receive a compressed fluid therefrom;   a turbine mounted on the engine shaft downstream of the combustor to provide a rotational force to the compressor; and   a monolithic composite component connected to the engine shaft, the monolithic composite component comprising:
 a continuous fiber blade including an airfoil extending radially outward from a root to a tip and a blade attachment feature positioned at or adjacent to the root; 
 a platform coupled to the root of the continuous fiber blade, the platform including a plurality of chopped fibers; and 
 a thermoplastic polymer contained in both the continuous fiber blade and the platform, 
   wherein the continuous fiber blade and platform are coupled together such that the continuous fiber blade and platform form a monolithic composite body.   
     
     
         12 . The gas turbine engine of  claim 11 , wherein the thermoplastic polymer includes a bonding layer between the continuous fiber blade and the platform. 
     
     
         13 . The gas turbine engine of  claim 11 , wherein the continuous fiber blade defines a pressure side and a suction side, and wherein the platform is coupled to the pressure side or suction side of the continuous fiber blade. 
     
     
         14 . The gas turbine engine of  claim 11 , wherein the platform comprises a split platform defining a notch such that the continuous fiber blade is received within the notch and coupled to the split platform at the notch. 
     
     
         15 . The gas turbine engine of  claim 11 , wherein the gas turbine engine includes a plurality of monolithic composite components, wherein a portion of the monolithic composite components are arranged circumferentially about the centerline to form a stage. 
     
     
         16 . The gas turbine engine of  claim 15 , wherein the platforms of each of the plurality of monolithic composite components extend at least partially in a circumferential direction relative to the centerline, and wherein the platform of at least two adjacent monolithic composite components of the portion of the monolithic composite components define a butt joint therebetween in the circumferential direction. 
     
     
         17 . A method of forming a monolithic composite component for a gas turbine engine, the method comprising:
 molding a continuous fiber thermoplastic composite into a continuous fiber blade including an airfoil extending radially outward from a root to a tip and a blade attachment feature positioned at or adjacent to the root;   forming a plurality of chopped fibers into a platform containing a thermoplastic polymer; and   coupling the platform to the root of the continuous fiber blade such that the platform and continuous fiber blade form the monolithic composite component.   
     
     
         18 . The method of  claim 17 , wherein forming the plurality of chopped fibers into the platform comprises at least one of compression molding or injection molding of the chopped fibers. 
     
     
         19 . The method of  claim 17 , wherein coupling the platform to the root of the continuous fiber blade comprises utilizing injection molding at an interface between the platform and the continuous fiber blade. 
     
     
         20 . The method of  claim 18 , wherein coupling the platform to the root of the continuous fiber blade comprises simultaneously coupling the platform to the continuous fiber blade while molding the platform.