Open-cell reticulated foam

Abstract

A foam for use in a lost-foam casting process utilized in the manufacture of a component for a gas turbine engine, the foam having a void fraction less than or equal to ninety five percent, is disclosed. The foam may include a first layer comprising polymer foam having an open-cell structure and a void fraction greater than ninety five percent. A second layer, comprising adhesive, may be adhered to the first layer. A third layer comprising particulate material may be adhered to the second layer.

What is claimed is: 
     
         1 . A foam for forming a gas turbine engine fan blade using a lost-foam casting process, the foam having a void fraction less than or equal to ninety five percent, comprising:
 a first layer, the first layer comprising a polymer foam having an open-cell structure and a void fraction greater than ninety five percent;   a second layer, the second layer comprising an adhesive adhered to the first layer; and   a third layer, the third layer comprising a particulate material, the third layer adhered to the second layer.   
     
     
         2 . The modified foam according to  claim 1 , wherein the polymer foam is selected from the group consisting of polyurethane polymer foam, polyvinyl chloride polymer foam, polystyrene polymer foam, polyimide polymer foam, silicone polymer foam, polyethylene polymer foam, polyester polymer foam, polypropylene foam and combinations thereof. 
     
     
         3 . The foam according to  claim 1 , wherein the adhesive is an adhesive polymer selected from the group consisting of acrylic polymer, alkyd polymer, styrene acrylic polymer, styrene butadiene polymer, vinyl acetate polymer, vinyl acetate homopolymer polymer, vinyl acrylic polymer, vinyl maleate polymer, vinyl versatate polymer, vinyl alcohol polymer, polyvinyl chloride polymer, polyvinylpyrrolidone polymer, casein and combinations thereof. 
     
     
         4 . The foam according to  claim 1 , wherein the particulate material is selected from the group consisting of wax powder, wood flour, polymer powder and combinations thereof. 
     
     
         5 . The foam according to  claim 4 , wherein the wax powder is selected from the group consisting of animal wax powder, vegetable wax powder, mineral wax powder, petroleum wax powder and combinations thereof. 
     
     
         6 . The foam according to  claim 4 , wherein the polymer powder is selected from the group consisting of polyurethane polymer powder, polyvinyl chloride polymer powder, polystyrene polymer powder, polyimide polymer powder, polyethylene polymer powder, polyester polymer powder, polypropylene polymer powder and combinations thereof. 
     
     
         7 . A method of manufacturing foam for forming a gas turbine engine fan blade using a lost-foam casting process, the foam having a void fraction less than or equal to ninety five percent, comprising:
 providing a polymer foam having an open-cell structure and a void fraction greater than ninety five percent;   coating the polymer foam with an adhesive; and   applying a particulate material to the adhesive.   
     
     
         8 . The method of manufacturing the foam according to  claim 7 , wherein the polymer foam is selected from the group consisting of polyurethane polymer foam, polyvinyl chloride polymer foam, polystyrene polymer foam, polyimide polymer foam, silicone polymer foam, polyethylene polymer foam, polyester polymer foam, polypropylene foam and combinations thereof. 
     
     
         9 . The method of manufacturing the foam according to  claim 7 , wherein the adhesive comprises an adhesive polymer, the adhesive polymer selected from the group consisting of acrylic polymer, alkyd polymer, styrene acrylic polymer, styrene butadiene polymer, vinyl acetate polymer, vinyl acetate homopolymer polymer, vinyl acrylic polymer, vinyl maleate polymer, vinyl versatate polymer, vinyl alcohol polymer, polyvinyl chloride polymer, polyvinylpyrrolidone polymer, casein and combinations thereof. 
     
     
         10 . The method of manufacturing the foam according to  claim 7 , wherein the particulate material is selected from the group consisting of wax powder, wood flour, polymer powder and combinations thereof. 
     
     
         11 . The method of manufacturing the foam according to  claim 10 , wherein the wax powder is selected from the group consisting of animal wax powder, vegetable wax powder, mineral wax powder, petroleum wax powder and combinations thereof. 
     
     
         12 . The method of manufacturing the foam according to  claim 10 , wherein the polymer powder is selected from the group consisting of polyurethane polymer powder, polyvinyl chloride polymer powder, polystyrene polymer powder, polyimide polymer powder, polyethylene polymer powder, polyester polymer powder, polypropylene polymer powder and combinations thereof. 
     
     
         13 . The method of manufacturing the foam according to  claim 7 , wherein the coating the polymer foam with an adhesive step comprises applying an emulsion to the polymer foam, the emulsion comprising an adhesive polymer and solvent. 
     
     
         14 . The method of manufacturing the foam according to  claim 13 , further comprising removing excess solvent from the polymer foam before applying a particulate material to the adhesive. 
     
     
         15 . The method of manufacturing the foam according to  claim 7 , wherein the polymer foam comprises ligaments positioned between nodes, and further comprising heating the foam to a temperature above the melting temperature of the particulate material, followed by cooling the foam to a temperature below the melting temperature of the particulate material to form a substantially continuous coating of particulate material over the ligaments. 
     
     
         16 . The method of manufacturing the foam according to  claim 7 , wherein the applying a particulate material to the adhesive includes passing the adhesive coated polymer foam through a fluidized bed of particulate material.