1. An airfoil for a turbomachine, comprising:
a metal foam core formed into an airfoil shape, the metal form core including a closed-cell foam, an open-cell foam, or a combination of open-cell foam and closed-cell foam;
a composite skin formed from a fabric disposed over the metal foam core and forming an external surface of the airfoil shape; and
an attachment feature extending from the metal foam core, wherein the attachment feature includes a blade root or a flat disk, wherein the attachment feature includes a metal foam having a higher density than a density of the metal foam core;
wherein the metal foam core has a plurality of outermost voids, and wherein the composite skin includes a first composite material extending into and at least partially filling at least some of the plurality of outermost voids;
wherein the first composite material includes a polyamide; and
wherein the polyamide material extends into the outermost voids to at least partially fill the outermost voids.
2. The airfoil of claim 1, wherein the composite skin includes a carbon fiber composite.
3. The airfoil of claim 2, wherein the carbon fiber composite includes a carbon fabric.
4. The airfoil of claim 1, wherein the composite skin includes a second composite material overlaying the first composite material.
5. The airfoil of claim 4, wherein the second composite material is a carbon fiber composite.
6. The airfoil of claim 4, wherein the second composite material is bonded to the first composite material.
7. The airfoil of claim 1, wherein the polyamide is glass filled.
8. The airfoil of claim 1, wherein the turbomachine is a vanebox, and wherein the airfoil is a vane configured for use in the vanebox.
9. A gas turbine engine, comprising:
at least one of a fan and a compressor;
a combustor in fluid communication with the compressor;
a turbine in fluid communication with the combustor,
wherein at least one of the fan, compressor and the turbine include an airfoil having a metal foam core formed in an airfoil shape and a composite skin formed from a fabric disposed over the metal foam core; and
an attachment feature extending from the metal foam core, wherein the attachment feature includes a blade root or a flat disk, wherein the attachment feature includes a metal foam having a higher density than a density of the metal foam core;
wherein the metal foam core has a plurality of outermost voids, and the composite skin includes a first composite material comprising a polyamide material that extends into the outermost voids to at least partially fill the outermost voids.
10. The gas turbine engine of claim 9, wherein the airfoil is a fan blade.
11. The gas turbine engine of claim 9, wherein the metal foam core is a closed-cell foam.
12. The gas turbine engine of claim 9, wherein the composite skin includes a second composite material, and wherein the first composite material is reinforced by the second composite material.
13. The gas turbine engine of claim 12, wherein the second composite material includes a carbon fabric.
14. The gas turbine engine of claim 9, wherein the airfoil is configured as a vane.
15. A method for manufacturing an airfoil for a turbomachine, comprising:
forming a metal foam core into an airfoil shape;
affixing a composite skin formed from a fabric to the metal foam core; and
forming an attachment feature extending from the metal foam core, wherein the attachment feature includes a blade root or a flat disk, wherein the attachment feature includes a metal foam having a higher density than a density of the metal foam core;
wherein the metal foam core is formed to include a plurality of outermost voids, and wherein the composite skin is formed at least in part to include a composite material comprising a polyamide material that extends into at least some of the plurality of outermost voids.
16. The method of claim 15, wherein the composite skin is formed at least in part by injection molding the polyamide material into at least some of the plurality of outermost voids.
17. The method of claim 16, further comprising bonding a carbon fiber composite to the composite material.
18. The method of claim 15, wherein the metal foam core is machined into an airfoil shape.
The claims below are in addition to those above.
All refrences to claim(s) which appear below refer to the numbering after this setence.
1. A method for replenishing condiments and prepared foods in a serving display unit comprising the steps of:
providing a serving display unit having one or more compartments for holding one or more serving trays;
providing one-time-useable serving trays;
filling the one-time-useable serving trays with condiments or prepared foods;
inserting the one-time-useable serving trays into the compartments in the serving display unit.
2. The method of claim 1 wherein the trays comprise a material that is rigid enough to maintain a rectangular shape when filled with condiments and thin enough to have corners that are flexible to the touch and is formed by one of the processed of the group consisting of thermoforming, injection molding and blow molding.
3. The method of claim 1 wherein the tray is formed from a thermoform film that has an initial thickness between 100 and 1 mils.
4. The method of claim 1 wherein the tray is formed from a thermoform film that has an initial thickness between 75 and 1 mils.
5. The method of claim 1 wherein the tray is formed from a thermoform film that has an initial thickness between 50 and 1 mils.
6. The method of claim 1 wherein the tray has a rectangular shaped bowl and a top rim with rounded corners and corners at the floor are thin enough to collapse when finger pressure is applied to their outside surface.
7. The method of claim 1 wherein the bowl has a thickness between 55 and 1 mils.
8. The method of claim 1 wherein the tray comprises a standard size tray that resists crushing of a force between 160 and 1 pounds.
9. The method of claim 1 wherein the tray comprises a standard size tray that resists crushing of a force between 100 and 1 pounds.
10. The method of claim 1 wherein the tray comprises a standard size tray that resists crushing of a force between 50 and 1 pounds.
11. The method of claim 1 wherein the tray comprises a one sixth tray that holds up to 15 pounds before collapsing its rim and supports at least 30 pounds before collapsing or a one ninth tray that holds up to 20 pounds before collapsing at its rim and support 7 pounds before collapsing.
12. An apparatus for providing and holding an array of disposable trays for holding condiments comprising:
a base having a surface with one or more openings, each opening for receiving one size of a number of standard size condiment trays;
one or more disposable condiment trays arranged in the openings in the base, each condiment tray characterized by
a rim for resting on the surface of the base to support the condiment tray in the opening,
a bowl integral with the rim and extending through the opening in the surface, wherein the rim and bowl comprise thermoformed film rigid enough to maintain a rectangular shape when filled with condiments thin enough to have corners that are flexible to the touch.
13. The apparatus of claim 12 wherein the trays comprise a material that is rigid enough to maintain a rectangular shape when filled with condiments and thin enough to have corners that are flexible to the touch.
14. The apparatus of claim 12 wherein the tray is formed from a thermoform film that has an initial thickness between 100 and 1 mils.
15. The apparatus of claim 12 wherein the tray is formed from a thermoform film that has an initial thickness between 75 and 1 mils.
16. The apparatus of claim 12 wherein the tray is formed from a thermoform film that has an initial thickness between 50 and 1 mils.
17. The apparatus of claim 12 wherein the tray has a rectangular shaped bowl and a top rim with rounded corners and corners at the floor are thin enough to collapse when finger pressure is applied to their outside surface.
18. The apparatus of claim 12 wherein the bowl has a thickness between 55 and 1 mils.
19. The apparatus of claim 12 wherein the tray comprises a standard size tray that resists crushing of a force between 160 and 1 pounds.
20. The apparatus of claims 12 wherein the tray comprises a standard size tray that resists crushing of a force between 100 and 1 pounds.
21. The apparatus of claim 12 wherein the tray comprises a standard size tray that resists crushing of a force between 50 and 1 pounds.
22. The apparatus of claim 12 wherein the tray is formed by thermoforming, injection molding or blow molding.
23. The apparatus of claim 12 wherein the tray comprises a one sixth tray that holds up to 15 pounds before collapsing its rim and supports at least 30 pounds before collapsing or a one ninth tray that holds up to 20 pounds before collapsing at its rim and support 7 pounds before collapsing.
24. A method for supplying and replenishing condiments and prepared foods in a serving display unit comprising the steps of:
providing a plurality of one-time-useable serving trays;
filling the one-time-useable serving trays with condiments or prepared foods;
attaching a film lid to the filled trays to protect their contents;
inserting the one-time-useable serving trays into compartments of the serving display unit; and
removing the lid from the trays to expose the contents for use by staff or customers.
25. The method of claim 24 wherein the trays comprise a material that is rigid enough to maintain a rectangular shape when filled with condiments and thin enough to have corners that are flexible to the touch.
26. The method of claim 24 wherein the tray is formed from a thermoform film that has an initial thickness between 100 and 1 mils.
27. The method of claim 24 wherein the tray is formed from a thermoform film that has an initial thickness between 75 and 1 mils.
28. The method of claim 24 wherein the tray is formed from a thermoform film that has an initial thickness between 50 and 1 mils.
29. The method of claim 24 wherein the tray has a rectangular shaped bowl and a top rim with rounded corners and corners at the floor are thin enough to collapse when finger pressure is applied to their outside surface.
30. The method of claim 24 wherein the bowl has a thickness between 55 and 1 mils.
31. The method of claim 24 wherein the tray comprises a standard size tray that resists crushing of a force between 160 and 1 pounds.
32. The method of claim 24 wherein the tray comprises a standard size tray that resists crushing of a force between 100 and 1 pounds.
33. The method of claim 24 wherein the tray comprises a standard size tray that resists crushing of a force between 50 and 1 pounds.
34. The method of claim 24 wherein the tray comprises a one sixth tray that holds up to 15 pounds before collapsing its rim and supports at least 30 pounds before collapsing or a one ninth tray that holds up to 20 pounds before collapsing at its rim and support 7 pounds before collapsing.