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US20040118978A1 - Helicopter rotor and method of repairing same - Google Patents

Helicopter rotor and method of repairing same Download PDF

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Publication number
US20040118978A1
US20040118978A1 US10/326,995 US32699502A US2004118978A1 US 20040118978 A1 US20040118978 A1 US 20040118978A1 US 32699502 A US32699502 A US 32699502A US 2004118978 A1 US2004118978 A1 US 2004118978A1
Authority
US
United States
Prior art keywords
blade
leading edge
aerofoil
section
resilient polymer
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US10/326,995
Inventor
Bruce Anning
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Advanced Composite Structures Inc
Original Assignee
Advanced Composite Structures Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Advanced Composite Structures Inc filed Critical Advanced Composite Structures Inc
Priority to US10/326,995 priority Critical patent/US20040118978A1/en
Assigned to ADVANCED COMPOSITE STRUCTURES INC. reassignment ADVANCED COMPOSITE STRUCTURES INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ANNING, BRUCE D.
Priority to CA2453635A priority patent/CA2453635C/en
Publication of US20040118978A1 publication Critical patent/US20040118978A1/en
Priority to US10/987,184 priority patent/US7237751B2/en
Abandoned legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B64—AIRCRAFT; AVIATION; COSMONAUTICS
    • B64C—AEROPLANES; HELICOPTERS
    • B64C11/00—Propellers, e.g. of ducted type; Features common to propellers and rotors for rotorcraft
    • B64C11/16—Blades
    • B64C11/20—Constructional features
    • B64C11/205—Constructional features for protecting blades, e.g. coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B64—AIRCRAFT; AVIATION; COSMONAUTICS
    • B64C—AEROPLANES; HELICOPTERS
    • B64C27/00—Rotorcraft; Rotors peculiar thereto
    • B64C27/32—Rotors
    • B64C27/46—Blades
    • B64C27/473—Constructional features

Definitions

  • the present invention relates to aerofoils, and more particularly to the protection of aerofoil leading edges from erosion damage.
  • the invention has particular application to rotary wings, for example helicopter rotor blades.
  • the leading edges of helicopter rotor blades are subject to environmental wear, particularly when the helicopter is operated in harsh conditions, for example with significant quantities of ambient sand or salt. It has been found in particular that there is a recurring problem of skin erosion located inboard of the metal leading edge abrasion strips in main rotor blades. Current practice is to remove the blades from the helicopter and send them for repair. In some cases, the damage cannot be repaired The damage requires skin repairs to the leading edge with reinforcement doublers applied. It has been found that a metal skin repair in the flex section of the blade is prone to delamination.
  • Impact damage is another significant concern with rotor blades since impact damage to the blade also requires removal of the blade and shipping to specialized shop capable of performing the repairs.
  • the present invention is concerned with an alternative arrangement that ameliorates many of the problems with current repair techniques for aerofoil leading edges.
  • an aerofoil for use in an aircraft, the aerofoil having a leading edge and a wear resistant, resilient polymeric material extending along at least a portion of the leading edge.
  • the polymeric leading edge has been found to provide good resistance to erosion. It has been found to be particularly effective in the flex section of helicopter main rotor blades as the flexibility of the material limits any tendency to delaminate as occurs with rigid metal leading edge repairs in this section of the blade.
  • the high centrifugal forces on the polymer may cause creep of the material, leading to the polymer disengaging off the end of the blade.
  • the polymer leading edge is, in this environment, preferably limited to the flex section of the blade, with the flight section being equipped with a conventional metal leading edge.
  • a method of protecting the leading edge of an aerofoil from erosion comprising securing to the leading edge a layer of resilient polymeric material.
  • the method preferably comprises securing the resilient polymer to the leading edge of the flex section.
  • the resilient polymer is preferably an elastomeric material, for example polyurethane.
  • the currently preferred material is ether urethane 85 Shore A polyurethane, desirably black in colour with a matte finish and UV stabilized. It is preferably bonded to the leading edge skin using an adhesive and with a bond line thickness control medium. This may be a scrim cloth.
  • the currently preferred adhesive is an epoxy adhesive, Hysol EA 9309.3NA containing 5-mil glass beads for bond line thickness control. It is preferably cured at an elevated temperature, with a uniform pressure applied over the polyurethane.
  • FIG. 1 is a plan view of a helicopter rotor blade
  • FIG. 2 is an exploded section along line II-II of FIG. 1;
  • FIG. 3 is an exploded isometric of a leading edge repair.
  • a blade 10 for use in a helicopter main rotor.
  • the blade has a mounting end 12 carrying a mounting fitting 14 which is used to mount the blade on the rotor hub of the aircraft.
  • the opposite end of the blade is the blade tip 16 .
  • That section of the blade adjacent the tip is the flight section 18 which, because it is furthest from the axis of rotation, travels at the greatest speed and provides the majority of lift.
  • Inboard of the flight section, 18 is the flex section 20 which, in use, undergoes bending deflection under the lift forces exerted on the blade.
  • the entire blade has an aerofoil shape as shown most particularly in FIG. 2.
  • the leading edge 22 of the blade is subject to erosion during use.
  • the erosion is most pronounced in the flight section where the speed of the blade is highest.
  • the rotor is equipped with an erosion strip 24 .
  • wear of the erosion strip reaches an unacceptable level, it is removed and replaced.
  • the worn skin of the rotor is abraded and cleaned and equipped with a polyurethane leading edge strip 26 as edge protection.
  • the bonding surface 30 of a polyurethane strip 32 is also abraded and cleaned with a solvent.
  • Adhesive 34 is applied to the abraded bonding surfaces of the blade and the polyurethane strip.
  • a scrim cloth 36 in this case 0.008 inch (00.2 mm.)nylon is positioned smoothly over the repair area, leaving no wrinkles or creases.
  • the polyurethane strip 32 is then positioned on the repair area over the scrim cloth and subjected to a uniform pressure of 15 psi (10 5 N/m 2 ) and an elevated temperature (e.g. 180° F. (82° C.) for a duration sufficient to cure the adhesive. It has been found that good conformity to the original shape of the blade and uniform adhesion are achieved through the use of a pressurized bladder acting on the outer surface of the polymeric sheet during curing of the adhesive.

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  • Engineering & Computer Science (AREA)
  • Aviation & Aerospace Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)

Abstract

An aerofoil, particularly a helicopter main rotor blade has a leading edge protector comprising a strip of resilient polymer, preferably polyurethane, adhered to the leading edge of the blade.

Description

    FIELD OF THE INVENTION
  • The present invention relates to aerofoils, and more particularly to the protection of aerofoil leading edges from erosion damage. The invention has particular application to rotary wings, for example helicopter rotor blades. [0001]
    • BACKGROUND
  • The invention was developed in the environment of helicopter rotor blade repair, and will be described primarily in connection with that application. It will be understood by those knowledgeable in the art that the invention may have wider application to aerofoils for other purposes. [0002]
  • The leading edges of helicopter rotor blades are subject to environmental wear, particularly when the helicopter is operated in harsh conditions, for example with significant quantities of ambient sand or salt. It has been found in particular that there is a recurring problem of skin erosion located inboard of the metal leading edge abrasion strips in main rotor blades. Current practice is to remove the blades from the helicopter and send them for repair. In some cases, the damage cannot be repaired The damage requires skin repairs to the leading edge with reinforcement doublers applied. It has been found that a metal skin repair in the flex section of the blade is prone to delamination. [0003]
  • Impact damage is another significant concern with rotor blades since impact damage to the blade also requires removal of the blade and shipping to specialized shop capable of performing the repairs. [0004]
  • Either repair, of erosion or impact damage can mean several weeks downtime for the aircraft while the blade is dismounted, packed and shipped, repaired and returned. [0005]
  • The present invention is concerned with an alternative arrangement that ameliorates many of the problems with current repair techniques for aerofoil leading edges. [0006]
    • SUMMARY
  • According to one aspect of the present invention there is provided an aerofoil for use in an aircraft, the aerofoil having a leading edge and a wear resistant, resilient polymeric material extending along at least a portion of the leading edge. [0007]
  • The polymeric leading edge has been found to provide good resistance to erosion. It has been found to be particularly effective in the flex section of helicopter main rotor blades as the flexibility of the material limits any tendency to delaminate as occurs with rigid metal leading edge repairs in this section of the blade. On the other hand, it is to be noted that when used in the outboard flight section of a helicopter rotor, the high centrifugal forces on the polymer may cause creep of the material, leading to the polymer disengaging off the end of the blade. In consequence, the polymer leading edge is, in this environment, preferably limited to the flex section of the blade, with the flight section being equipped with a conventional metal leading edge. [0008]
  • Minor impact damage to a polymeric leading edge can readily be repaired in the field rather than dismounting the blade and shipping it away for repair, as would be the case with damage to a conventional leading edge. [0009]
  • According to another aspect of the present invention there is provided a method of protecting the leading edge of an aerofoil from erosion, comprising securing to the leading edge a layer of resilient polymeric material. [0010]
  • The installation of the polymeric leading edge is much more easily performed than the installation of a metal leading edge. It conforms more closely to the blade configuration since the metal edge is conventionally shaped using a brake, forming a sequence of substantially flat segments only approximating the smooth, uniform curvature of the original blade. [0011]
  • Where the aerofoil is a rotor blade for a rotary wing aircraft with a mounting end for attachment to a rotor drive, a flight section adjacent a blade tip, opposite the mounting end and a flex section between the flight section and the mounting end, the method preferably comprises securing the resilient polymer to the leading edge of the flex section. [0012]
  • The resilient polymer is preferably an elastomeric material, for example polyurethane. The currently preferred material is ether urethane 85 Shore A polyurethane, desirably black in colour with a matte finish and UV stabilized. It is preferably bonded to the leading edge skin using an adhesive and with a bond line thickness control medium. This may be a scrim cloth. [0013]
  • The currently preferred adhesive is an epoxy adhesive, Hysol EA 9309.3NA containing 5-mil glass beads for bond line thickness control. It is preferably cured at an elevated temperature, with a uniform pressure applied over the polyurethane.[0014]
    • BRIEF DESCRIPTION OF THE DRAWINGS
  • In the accompanying drawings, which illustrate an exemplary embodiment of the present invention: [0015]
  • FIG. 1 is a plan view of a helicopter rotor blade; [0016]
  • FIG. 2 is an exploded section along line II-II of FIG. 1; and [0017]
  • FIG. 3 is an exploded isometric of a leading edge repair.[0018]
    • DETAILED DESCRIPTION
  • Referring to the accompanying drawings, there is illustrated a [0019] blade 10 for use in a helicopter main rotor. The blade has a mounting end 12 carrying a mounting fitting 14 which is used to mount the blade on the rotor hub of the aircraft. The opposite end of the blade is the blade tip 16. That section of the blade adjacent the tip is the flight section 18 which, because it is furthest from the axis of rotation, travels at the greatest speed and provides the majority of lift. Inboard of the flight section, 18 is the flex section 20 which, in use, undergoes bending deflection under the lift forces exerted on the blade.
  • The entire blade has an aerofoil shape as shown most particularly in FIG. 2. [0020]
  • The leading [0021] edge 22 of the blade is subject to erosion during use. The erosion is most pronounced in the flight section where the speed of the blade is highest. To limit erosion in the flight section, the rotor is equipped with an erosion strip 24. When wear of the erosion strip reaches an unacceptable level, it is removed and replaced. With the present invention, For leading edge wear inboard of the erosion strip, the worn skin of the rotor is abraded and cleaned and equipped with a polyurethane leading edge strip 26 as edge protection.
    • EXAMPLE
  • With the illustrated [0022] blade 10, the repair area of the blade is marked off. It is then abraded and cleaned with an appropriate solvent.
  • The [0023] bonding surface 30 of a polyurethane strip 32 is also abraded and cleaned with a solvent.
  • [0024] Adhesive 34 is applied to the abraded bonding surfaces of the blade and the polyurethane strip.
  • A [0025] scrim cloth 36, in this case 0.008 inch (00.2 mm.)nylon is positioned smoothly over the repair area, leaving no wrinkles or creases.
  • The [0026] polyurethane strip 32 is then positioned on the repair area over the scrim cloth and subjected to a uniform pressure of 15 psi (105 N/m2) and an elevated temperature (e.g. 180° F. (82° C.) for a duration sufficient to cure the adhesive. It has been found that good conformity to the original shape of the blade and uniform adhesion are achieved through the use of a pressurized bladder acting on the outer surface of the polymeric sheet during curing of the adhesive.
  • This produces the polyurethane leading [0027] edge protector 26 in the flex section, abutting the metal edge protection used in the flight section at a junction 38 where the edge of the metal sheet of the flight section edge protection 24 provides a surface against which the outboard edge of the polyurethane sheet 32 engages, to support the polyurethane sheet against creep owing to the centrifugal force that is generated during operation of the blade.
  • While one particular embodiment of the present invention has been described in the foregoing, it is to be understood that other embodiments are possible within the scope of the appended claims. Thus, while the present invention has been described in connection with its application to helicopter main rotor blades, it is to be understood that the invention has application to other aerofoils that require edge protection. Examples may include the wings of fixed wing aircraft and the leading edges of aircraft propellers. The invention is therefore to be considered limited solely to the scope of the appended claims. [0028]

Claims (11)

Embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:
1. An aerofoil for use in an aircraft, the aerofoil having a leading edge and a wear resistant polymeric material extending along at least a portion of the leading edge.
2. An aerofoil according to claim 1 wherein the polymeric material is an elastomer.
3. An aerofoil according to claim 1 wherein the polymeric material is polyurethane.
4. An aerofoil according to claim 1, wherein the aerofoil is a rotor blade for a rotating wing aircraft.
5. An aerofoil according to claim 4 wherein the rotor blade has an inboard end section for attachment to a rotor drive, an outboard flight section adjacent an outboard tip end of the blade and a flexible blade section between the inboard and outboard sections of the blade, the polymeric material being applied to the leading edge of the flexible blade section.
6. A method of protecting the leading edge of an aerofoil from erosion, comprising securing to the leading edge a layer of resilient polymer material.
7. A method according to claim 6 wherein the aerofoil is a rotor blade for a rotary wing aircraft with an inboard mounting end for attachment to a rotor drive, a flight section adjacent an outboard blade tip opposite the mounting end and a flex section between the flight section and the mounting end, the method comprising securing the resilient polymer to the leading edge of the flex section.
8. A method according to claim 6 wherein the resilient polymer is an elastomeric material.
9. A method according to claim 6, wherein the resilient polymer is polyurethane.
10. A method according to claim 6 comprising applying a bond line thickness control medium to the leading edge and applying the resilient polymer to the thickness control medium.
11. A method according to claim 10 wherein the bond line thickness control medium is a scrim cloth.
US10/326,995 2002-12-24 2002-12-24 Helicopter rotor and method of repairing same Abandoned US20040118978A1 (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
US10/326,995 US20040118978A1 (en) 2002-12-24 2002-12-24 Helicopter rotor and method of repairing same
CA2453635A CA2453635C (en) 2002-12-24 2003-12-18 Helicopter rotor and method of repairing same
US10/987,184 US7237751B2 (en) 2002-12-24 2004-11-15 Helicopter rotor and method of repairing same

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US10/326,995 US20040118978A1 (en) 2002-12-24 2002-12-24 Helicopter rotor and method of repairing same

Related Child Applications (1)

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US10/987,184 Continuation-In-Part US7237751B2 (en) 2002-12-24 2004-11-15 Helicopter rotor and method of repairing same

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US10/987,184 Expired - Fee Related US7237751B2 (en) 2002-12-24 2004-11-15 Helicopter rotor and method of repairing same

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US20050099778A1 (en) * 2003-11-11 2005-05-12 Sumitomo Wiring Systems, Ltd. Circuit assembly and method for producing the same
US20050271881A1 (en) * 2004-05-24 2005-12-08 Hong Shek C Abrasion resistant coatings
WO2007075497A3 (en) * 2005-12-14 2007-10-04 Hontek Corp Method and coating for protecting and repairing an airfoil surface
US20080159870A1 (en) * 2006-12-14 2008-07-03 Hontek Corporation Method and coating for protecting and repairing an airfoil surface using molded boots, sheet or tape
ES2333929A1 (en) * 2007-10-18 2010-03-02 Fundacion Cener-Ciemat REMOVABLE PROTECTION OF THE ATTACK EDGE ON A WINDER BLADE.
GB2483672A (en) * 2010-09-15 2012-03-21 Ge Aviat Systems Ltd Propeller blade having icephobic coating
US20120104166A1 (en) * 2010-10-29 2012-05-03 Airbus Operations, S.L. Inner bent repairment
WO2013092211A1 (en) * 2011-12-19 2013-06-27 Lm Wind Power A/S An erosion shield for a wind turbine blade
EP2724855A1 (en) 2012-10-24 2014-04-30 Eurocopter Deutschland GmbH Method of producing a composite plastic erosion protection cap and a composite plastic erosion protection cap
US8851858B2 (en) 2011-08-26 2014-10-07 Ge Aviation Systems Limited Propeller blades having icephobic coating
US8961142B2 (en) 2009-04-10 2015-02-24 Xemc Darwind B.V. Protected wind turbine blade, a method of manufacturing it and a wind turbine
EP2915743A1 (en) * 2014-03-03 2015-09-09 European Aeronautic Defence and Space Company - EADS France Sheet for protecting the leading edges of aircraft wings
US20180209400A1 (en) * 2015-07-17 2018-07-26 Lm Wp Patent Holding A/S A wind turbine blade having an erosion shield
EP3218597B1 (en) 2014-11-10 2019-03-27 Polytech A/S Polyurethane material, process for preparing such material and protective cover for wind turbine blade
CN109969385A (en) * 2017-12-28 2019-07-05 辽宁壮龙无人机科技有限公司 UAV and its propeller
US10995242B2 (en) 2015-06-25 2021-05-04 Patentco Aps Coating system for coating a surface of a substrate
US20250026493A1 (en) * 2023-07-19 2025-01-23 The Boeing Company Methods and apparatus to repair composite airfoil structures

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US8556589B2 (en) * 2009-06-24 2013-10-15 Teledyne Scientific & Imaging, Llc Hybrid composite for erosion resistant helicopter blades
US20120096714A1 (en) * 2009-07-16 2012-04-26 Bell Helicopter Textron Inc. Method of Applying Abrasion Resistant Materials to Rotors
US8770942B2 (en) * 2011-01-26 2014-07-08 Fujikura Rubber Ltd Blade and laminated protective sheet for the blade
US8425196B2 (en) * 2011-01-28 2013-04-23 General Electric Company Wind turbine blades with a hardened substrate construction
US8826534B2 (en) 2011-12-16 2014-09-09 Sikorsky Aircraft Corporation Rotor blade repair structure and method
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US10316818B2 (en) * 2016-03-21 2019-06-11 General Electric Company Thermoset component having a weldable thermoplastic interface
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US20050099778A1 (en) * 2003-11-11 2005-05-12 Sumitomo Wiring Systems, Ltd. Circuit assembly and method for producing the same
US8124235B2 (en) 2004-05-24 2012-02-28 Hontek Corporation Method of making matte airfoil coatings
US20050271881A1 (en) * 2004-05-24 2005-12-08 Hong Shek C Abrasion resistant coatings
US8557388B2 (en) 2004-05-24 2013-10-15 Hontek Corporation Erosion resistant coatings for leading edges of airfoils
US9732232B2 (en) 2004-05-24 2017-08-15 Hontek Corporation Abrasion resistant coatings
US10557038B2 (en) 2004-05-24 2020-02-11 Hontek Corporation Erosion resistant coatings
US7736745B2 (en) * 2004-05-24 2010-06-15 Hontek Corporation Abrasion resistant coatings
US20100249295A1 (en) * 2004-05-24 2010-09-30 Hontek Corporation Abrasion resistant coatings
US20100256296A1 (en) * 2004-05-24 2010-10-07 Hontek Corporation Abrasion resistant coatings
US9663663B2 (en) 2004-05-24 2017-05-30 Hontek Corporation Airfoil leading edge coatings
US8091227B2 (en) 2005-12-14 2012-01-10 Hontek Corporation Method of repairing an airfoil surface
WO2007075497A3 (en) * 2005-12-14 2007-10-04 Hontek Corp Method and coating for protecting and repairing an airfoil surface
EP3305465A1 (en) * 2005-12-14 2018-04-11 Hontek Corporation Method and coating for protecting and repairing an airfoil surface
US9770791B2 (en) 2005-12-14 2017-09-26 Hontek Corporation Method for repairing an airfoil surface having an elastomeric protective coating
EP2502679A3 (en) * 2005-12-14 2013-01-09 Hontek Corporation Method and coating for protecting and repairing an airfoil surface
US20070231156A1 (en) * 2005-12-14 2007-10-04 Hontek Corporation Method and coating for protecting and repairing an airfoil surface
US20110158807A1 (en) * 2006-12-14 2011-06-30 Hong Shek C Method and coating for protecting and repairing an airfoil surface using molded boots, sheet or tape
US20080159870A1 (en) * 2006-12-14 2008-07-03 Hontek Corporation Method and coating for protecting and repairing an airfoil surface using molded boots, sheet or tape
EP2167382A4 (en) * 2007-06-13 2011-08-03 Hontek Corp METHOD AND COATING FOR PROTECTING AND REPAIRING A PORTABLE SURFACE USING MOLDED SHEETS, SHEETS OR STRIPS
ES2333929A1 (en) * 2007-10-18 2010-03-02 Fundacion Cener-Ciemat REMOVABLE PROTECTION OF THE ATTACK EDGE ON A WINDER BLADE.
US8961142B2 (en) 2009-04-10 2015-02-24 Xemc Darwind B.V. Protected wind turbine blade, a method of manufacturing it and a wind turbine
GB2483672B (en) * 2010-09-15 2017-01-18 Ge Aviat Systems Ltd Propeller blades having icephobic coating
GB2483672A (en) * 2010-09-15 2012-03-21 Ge Aviat Systems Ltd Propeller blade having icephobic coating
US20120104166A1 (en) * 2010-10-29 2012-05-03 Airbus Operations, S.L. Inner bent repairment
US8584986B2 (en) * 2010-10-29 2013-11-19 Airbus Operations, S.L. Inner bent repairment
US8851858B2 (en) 2011-08-26 2014-10-07 Ge Aviation Systems Limited Propeller blades having icephobic coating
WO2013092211A1 (en) * 2011-12-19 2013-06-27 Lm Wind Power A/S An erosion shield for a wind turbine blade
CN104254687B (en) * 2011-12-19 2017-08-29 Lm Wp 专利控股有限公司 Corrosion protection for wind turbine blades
US9752444B2 (en) 2011-12-19 2017-09-05 Lm Wp Patent Holding A/S Erosion shield for a wind turbine blade
CN104254687A (en) * 2011-12-19 2014-12-31 Lmwp专利控股有限公司 An erosion shield for a wind turbine blade
EP2724855A1 (en) 2012-10-24 2014-04-30 Eurocopter Deutschland GmbH Method of producing a composite plastic erosion protection cap and a composite plastic erosion protection cap
US10266247B2 (en) 2014-03-03 2019-04-23 Airbus Sas Protective mat for leading edges of airfoil elements
EP2915743A1 (en) * 2014-03-03 2015-09-09 European Aeronautic Defence and Space Company - EADS France Sheet for protecting the leading edges of aircraft wings
EP3218597B1 (en) 2014-11-10 2019-03-27 Polytech A/S Polyurethane material, process for preparing such material and protective cover for wind turbine blade
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CA2453635C (en) 2010-01-26
US20050169763A1 (en) 2005-08-04
CA2453635A1 (en) 2004-06-24
US7237751B2 (en) 2007-07-03

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