3D Printed Carbon-Bonded Composite via Additive Manufacturing
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Solution Overview
Problem
The fabrication of carbon-bonded fiber composites (CBFCs) and ceramic matrix composites (CMCs) is labor-intensive, time-consuming, and expensive, limiting their applications due to the complexity and cost of traditional manufacturing processes.
Innovation Solution
An additive manufacturing system that discharges a curable composition containing aromatic, actinically curable components, diluents, reinforcement, and a photoinitiator, which is partially cured and then pyrolyzed to form a three-dimensional printed carbon-bonded composite article with reduced porosity and increased char yield, eliminating the need for extensive subtractive machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional hand-layup fabrication process is used for CBFCs and CMCs, then the composite material achieves required strength and durability, but the manufacturing process becomes labor-intensive, time-consuming, and expensive
Solution Approach 1:
The patent replaces manual mechanical operations (hand-laying fibers, manual saturation with resin, repeated oven heating cycles) with an automated additive manufacturing system that deposits curable composition layer-by-layer under computer control, significantly reducing labor intensity and manufacturing time while maintaining composite material strength
Solution Approach 2:
The patent changes the chemical composition parameters by using specifically formulated curable compositions with controlled H/C atomic ratios (0.4-1.6) and controlled porosity (0-50%), which enable the material to achieve required strength properties while reducing the number of manufacturing cycles needed
2Temperature
If traditional pyrolysis process is used to convert resin to carbon, then the composite achieves high-temperature resistance, but porosity increases and requires repeated filling cycles
Solution Approach 1:
The patent performs preliminary action by controlling the porosity of the curable composition before pyrolysis (maintaining it at 0-50%), which pre-prevents excessive void formation during the subsequent pyrolysis process, thereby achieving high-temperature resistance without requiring repeated filling cycles to correct porosity defects
Solution Approach 2:
The patent changes the chemical composition parameters of the curable composition (H/C atomic ratio, aromatic content, viscosity) to optimize the pyrolysis reaction, enabling the material to transform into a dense, porous structure with controlled porosity that maintains high-temperature resistance while minimizing void formation
3Quantity of substance
If generically shaped blocks are produced through traditional fabrication, then the composite material achieves required density, but extensive subtractive machining is required to achieve desired net shape
Solution Approach 1:
The patent inverts the traditional manufacturing approach by using additive manufacturing to directly deposit curable composition in the desired final shape layer-by-layer, eliminating the need to first create a generic block and then perform extensive subtractive machining, thereby achieving both required density and desired net shape simultaneously
Solution Approach 2:
The patent applies local quality by enabling different regions of the composite structure to have different fiber orientations, reinforcement distributions, and composition formulations tailored to specific functional requirements, allowing complex geometries to be manufactured directly without machining while maintaining optimal material density and performance
4Manufacturing precision
If repeated saturation and pyrolysis cycles are performed to reduce porosity, then the composite achieves low porosity for intended application, but manufacturing time and cost increase significantly
Solution Approach 1:
The patent performs preliminary action by formulating the curable composition with controlled porosity (0-50%) before deposition, which pre-prevents excessive void formation and reduces the need for repeated saturation and pyrolysis cycles, thereby achieving low porosity while significantly reducing manufacturing cycle time
Solution Approach 2:
The patent enables continuous additive manufacturing deposition of curable composition layers followed by continuous pyrolysis processing, eliminating the discontinuous repeated cycles of traditional methods, thereby achieving low porosity structures more efficiently with reduced manufacturing time
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables the production of composite structures with enhanced properties and reduced manufacturing time and cost, allowing for the creation of complex shapes with minimal post-processing requirements, thus expanding their applications in high-temperature environments.
Implementation Method 1
irradiating the curable composition during the discharging to at least partially actinically cure the curable composition and form a preform
Implementation Method 2
pyrolyzing the preform to form the three-dimensional printed carbon-bonded composite article
Data Source
AI summary
A method is disclosed for us in additively manufacturing a three-dimensional carbon-bonded composite article. The method may include discharging from a print head a curable composition. The curable composition may include a) at least one aromatic, actinically curable component having an H/Catomic ratio of from 0.4 to 1.6, selected from the group consisting of (meth)acrylate oligomers, epoxy-functionalized compounds, oxetane-functionalized compounds and mixtures thereof; and b) at least one diluent comprising at least one actinically curable monomer. The curable composition may also include c) a reinforcement, and d) a photoinitiator. The method may further include irradiating the curable composition during the discharging to at least partially actinically cure the curable composition and form a preform of the three-dimensional carbon-bonded composite article. The method also includes pyrolyzing the preform to form the three-dimensional printed carbon-bonded composite article.