Composite vane and method of manufacture

Abstract

A vane having a profile capable of formation by pultrusion is disclosed. The vane can be used for removing liquids entrained in a gas stream. The vane includes a main curved section oriented generally parallel to the gas stream and curved to reorient the gas stream, the main curved section causing a first and a second change of direction of the gas stream; a first air pocket formed on a first side of the main curved section, the first air pocket sized and oriented into the gas stream where the gas stream first changes direction; and a second air pocket formed on a second side of the main curved section, the second air pocket smaller than the first air pocket and sized and oriented into the gas stream where the gas stream makes the second direction change.

1 - 19 . (canceled) 
   
   
       20 . A method for manufacturing a composite vane for use in removing liquid droplets from a gas stream, comprising:
 reinforcing a fiber material with one or more of fiberglass, carbon and aromatic polyamide;   pulling the impregnated reinforced fiber material through a die; and   simultaneous with the pulling step, applying heat at a constant temperature to the material, whereby the composite vane having a desired profile is formed, and whereby the desired profile comprises:
 a main curved section oriented generally parallel to the gas stream and curved to reorient the gas stream, the main curved section capable of causing a first and a second change of direction of the gas stream; 
 a first air pocket formed on a first side of the main curved section, the first air pocket located on the composite vane where the gas stream first changes direction; and 
 a second air pocket formed on a second side of the main curved section, the second air pocket smaller than the first air pocket and located on the composite vane where the gas stream makes the second direction change. 
   
   
   
       21 . The method of  claim 20  further comprising impregnating the reinforced fiber material with a thermosetting resin. 
   
   
       22 . The method of  claim 21 , wherein the impregnating fully impregnates the fiber material with the thermosetting resin such that all the fiber filaments are thoroughly saturated with the resin mixture. 
   
   
       23 . The method of  claim 21  wherein the thermosetting resin is combined with fillers, catalysts, and pigments. 
   
   
       23 . The method of  claim 21  wherein the thermosetting resin is selected from a group consisting of one or more of vinyl ester resin and epoxy resins 
   
   
       24 . The method of  claim 20  further comprising applying a surface veil to the composite vane to adjust surface wettability. 
   
   
       25 . The method of  claim 20  further comprising applying additional layers to the composite vane, wherein the layers operate to reduce visibility to radar 
   
   
       26 . The method of  claim 20  wherein the main curved section is formed with a smooth curve. 
   
   
       27 . The method of  claim 20  wherein the main curved section is formed with a series of flats approximating a smooth curve. 
   
   
       28 . The method of  claim 20  wherein the main curved section is formed with a thickness of about 3/16 inch and the first and the second pockets are defined by pocket walls having thicknesses of about ⅛ inch. 
   
   
       29 . The method of  claim 20  wherein the composite vane is formed with a width of about 5 inches and a length of between about 5 inches and about 144 inches. 
   
   
       30 . The method of  claim 20  further comprising:
 repeating the reinforcing, pulling and simultaneous applying heat steps to form a plurality of composite vanes; and   placing the plurality of composite vanes at a predetermined separation to remove the liquids from a gas stream.   
   
   
       31 . The method of  claim 30  wherein the placing places the plurality of composite vanes in a plenum housing the plurality of composite vanes. 
   
   
       32 . The method of  claim 31  further comprising coupling a coalescer to an exit from the plenum, the coalescer comprising a filter material to further remove the liquid droplets.