Composite airfoil

Abstract

A turbine component includes mounting structure for attaching the turbine component. A core is attached to the mounting structure. The core is made from a structural material. A plastic airfoil portion envelopes at least a portion of the core.

1 . A turbine component comprising:
 mounting structure for attaching the turbine component;   a core attached to the mounting structure, the core made from a structural material; and   a plastic airfoil portion enveloping at least a portion of the core.   
   
   
       2 . The turbine component of  claim 1  wherein the core has a leading edge and the airfoil portion envelopes at least the leading edge portion of the core. 
   
   
       3 . The turbine component of  claim 1  wherein the airfoil portion envelopes the entire core. 
   
   
       4 . The turbine component of  claim 1  wherein the core has at least one void therein. 
   
   
       5 . The turbine component of  claim 4  wherein the airfoil portion is made from an injection molded plastic material that extends at least partially into the void in the core. 
   
   
       6 . The turbine component of  claim 4  wherein the core has a plurality of voids extending through the core. 
   
   
       7 . The turbine component of  claim 6  wherein the airfoil portion is made from an injection molded plastic material that extends at least partially into the voids in the core. 
   
   
       8 . The turbine component of  claim 1  wherein the core is made from a material selected from the group of metal and ceramic. 
   
   
       9 . The turbine component of  claim 1  wherein the core and mounting structure are integrally formed as one piece. 
   
   
       10 . The turbine component of  claim 1  wherein the core is made from a forged, die cast or investment cast metal material formed into a desired shape. 
   
   
       11 . A turbine component comprising:
 mounting structure for attaching the turbine component;   a core attached to the mounting structure, the core made from a structural material and having at least one void formed in the core; and   an airfoil portion enveloping at least a portion of the core, the airfoil portion made from a plastic material that extends at least partially into the void in the core.   
   
   
       12 . The turbine component of  claim 11  wherein the core has a leading edge and the airfoil portion envelopes at least the leading edge portion of the core. 
   
   
       13 . The turbine component of  claim 11  wherein the airfoil portion envelopes the entire core. 
   
   
       14 . The turbine component of  claim 11  wherein the void extends through the core. 
   
   
       15 . The turbine component of  claim 11  wherein the core is made from a material selected from the group of metal and ceramic. 
   
   
       16 . The turbine component of  claim 11  wherein the core and mounting structure are integrally formed as one piece. 
   
   
       17 . The turbine component of  claim 11  wherein the airfoil portion is injection molded onto the core. 
   
   
       18 . A component for a gas turbine having a plurality of compressor and turbine stages, the component comprising:
 mounting structure for attaching the component to gas turbine structure;   a core integrally formed as one piece with the mounting structure, the core made from a material selected from the group of metal and ceramic and having a plurality of voids extending through the core; and   an airfoil enveloping the entire core, the airfoil made from an injection molded plastic material that extends at least partially into the voids in the core.   
   
   
       19 . The component of  claim 18  wherein the airfoil extends into and completely fills the voids in entire core. 
   
   
       20 . The component of  claim 18  wherein the component is used in one of the first gas turbine compressor stages.