Composite blade and method of manufacturing composite blade

1. A composite blade formed by laying up composite material layers in which reinforcement fibers are impregnated with resin in a thickness direction of the blade, the composite blade comprising:

a blade root provided on a base end side;

an airfoil provided on a tip side;

a first lay-up configured as a lay-up in which some of the composite material layers are laid up, the first lay-up being provided in the blade root so as to space parts of the composite material layers apart from each other starting from the base end side to form a plurality of spacing parts and so as to extend from the tip side toward the base end side in the thickness direction of the blade; and

a plurality of second lay-ups each configured as a lay-up in which some of the composite material layers are laid up, the second lay-ups being provided in the spacing parts in the first lay-up in the blade root so as to be lined up in the thickness direction of the blade, wherein

each of the second lay-ups has a first end and an opposite second end in a longitudinal direction of the composite blade, the second end of each second lay-up being arranged at the base end side,

among the plurality of second lay-ups, a second lay-up closer to a center side than to an outer side in the thickness direction of the blade is a larger distance from a proximal position to a top position,

the plurality of second lay-ups include a central lay-up that is disposed at the center in the thickness direction of the blade, and a plurality of outer lay-ups disposed closer to the outer side than the central lay-up is to the outer side in the thickness direction of the blade,

the central lay-up is formed so as to extend, from the first end of the central lay-up, outward in the thickness direction of the blade and then inward in the thickness direction of the blade, to the second end of the central lay-up,

an inner surface of each of the plurality of outer lay-ups are each curved to be concave to the center side in the thickness direction of the blade, and

among the plurality of outer lay-ups, the inner surface of an outer lay-up that is disposed closer to the center side in the thickness direction of the blade has a smaller curvature radius at the second end than that of the inner surface of an outer lay-up that is disposed closer to the outer side in the thickness direction of the blade.

2. The composite blade according to claim 1 , wherein a difference between the first ends of adjacent second lay-ups in the longitudinal direction of the composite blade is larger as the adjacent second lay-ups are closer to the center side than to the outer side in the thickness direction of the blade.

3. The composite blade according to claim 1 , wherein out of the plurality of second lay-ups, a second lay-up that is disposed closer to the center side in the thickness direction of the blade has a larger thickness in the thickness direction of the blade than a second lay-up that is disposed closer to the outer side in the thickness direction of the blade.

4. A composite blade formed by laying up composite material layers in which reinforcement fibers are impregnated with resin in a thickness direction of the blade, the composite blade comprising:

a blade root provided on a base end side;

an airfoil provided on a tip side;

a first lay-up configured as a lay-up in which some of the composite material layers are laid up, the first lay-up being provided in the blade root so as to space parts of the composite material layers apart from each other starting from the base end side to form a plurality of spacing parts and so as to extend from the tip side toward the base end side in the thickness direction of the blade;

a plurality of second lay-ups each configured as a lay-up in which some of the composite material layers are laid up, the second lay-ups being provided in the spacing parts in the first lay-up in the blade root so as to be lined up in the thickness direction of the blade; and

a foam layer formed of foaming resin and disposed at the center side of the airfoil in the thickness direction of the blade, wherein

among the plurality of second lay-ups, a second lay-up closer to a center side than to an outer side in the thickness direction of the blade is a larger distance from a proximal position to a top position,

a foam layer formed of foaming resin and disposed at the center side of the airfoil in the thickness direction of the blade, wherein

the foam layer is formed such that an end part has a wedge shape extending toward the base end side along a course of the end part from the outer side to the center side in the thickness direction of the blade, and

the first lay-up includes central layers that extend from the end part of the foam layer toward the base end side in the blade root.

5. The composite blade according to claim 4 , wherein the end part of the foam layer is provided in a range in which interlaminar tensile stress acts on the composite material layers.

6. The composite blade according to claim 4 , wherein the central layers include a cover layer as part of the composite material layers that is disposed closest to the center side in the thickness direction of the blade, the cover layer extending on the periphery of the foam layer and extending into the airfoil.

7. A method of manufacturing a composite blade formed by laying up composite material layers in which reinforcement fibers are impregnated with resin in a thickness direction of the blade, the composite blade including a blade root provided on a base end side and an airfoil provided on a tip side, the method comprising:

forming a first lay-up configured as a lay-up in which some of the composite material layers are laid up, the first lay-up being provided in the blade root so as to space parts of the composite material layers apart from each other starting from the base end side to form a plurality of spacing parts and so as to extend from the tip side toward the base end side in the thickness direction of the blade; and

forming a plurality of second lay-ups each configured as a lay-up in which some of the composite material layers are laid up, the second lay-ups being provided in the spacing parts in the first lay-up in the blade root so as to be lined up in the thickness direction of the blade, wherein

each of the second lay-ups has a first end and an opposite second end in a longitudinal direction of the composite blade, the second end of each second lay-up being arranged at the base end side,

among the plurality of second lay-ups, a second lay-up closer to a center side than to an outer side in the thickness direction of the blade is a larger distance from a proximal position to a top position,

the plurality of second lay-ups include a central lay-up that is disposed at the center in the thickness direction of the blade, and a plurality of outer lay-ups disposed closer to the outer side than the central lay-up is to the outer side in the thickness direction of the blade,

forming the first lay-up includes laying up the composite material layers for forming a part of the first lay-up in each step in a stepwise process to form the first lay-up, and

forming the second lay-up includes laying up, each time forming the first lay-up is performed, the composite material layers for forming the corresponding second lay-up on the composite material layers that have been laid up at forming the first lay-up performed immediately before so that

the central lay-up is formed so as to extend, from the first end of the central lay-up, outward in the thickness direction of the blade and then inward in the thickness direction of the blade, to the second end of the central lay-up,

inner surface of each of the plurality of outer lay-ups are each curved to be concave to the center side in the thickness direction of the blade, and

among the plurality of outer lay-ups, the inner surface of an outer lay-up that is disposed closer to the center side in the thickness direction of the blade has a smaller curvature radius at the second end than that of the inner surface of an outer lay-up that is disposed closer to the outer side in the thickness direction of the blade.

8. A method of manufacturing a composite blade formed by laying up composite material layers in which reinforcement fibers are impregnated with resin in a thickness direction of the blade, the composite blade including a blade root provided on a base end side and an airfoil provided on a tip side, the method comprising:

forming a first lay-up configured as a lay-up in which some of the composite material layers are laid up, the first lay-up being provided in the blade root so as to space parts of the composite material layers apart from each other starting from the base end side to form a plurality of spacing parts and so as to extend from the tip side toward the base end side in the thickness direction of the blade;

forming a plurality of second lay-ups each configured as a lay-up in which some of the composite material layers are laid up, the second lay-ups being provided in the spacing parts in the first lay-up in the blade root so as to be lined up in the thickness direction of the blade;

forming a foam layer of foaming resin so as to be disposed at the center side of the airfoil in the thickness direction of the blade, wherein

among the plurality of second lay-ups, a second lay-up closer to a center side than to an outer side in the thickness direction of the blade is a larger distance from a proximal position to a top position,

forming the first lay-up includes laying up the composite material layers for forming a part of the first lay-up in each step in a stepwise process to form the first lay-up,

forming the second lay-up includes laying up, each time forming the first lay-up is performed, the composite material layers for forming the corresponding second lay-up on the composite material layers that have been laid up at forming the first lay-up performed immediately before, and

forming the foam layer includes forming the foam layer such that an end part has a wedge shape extending toward the base end side along a course of the end part from the outer side to the center side in the thickness direction of the blade, and the first lay-up includes central layers that extend from the end part of the foam layer toward the base end side in the blade root.