Carbon/Carbon Composite Impregnation for Uniform Ceramic Distribution
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Solution Overview
Problem
Existing carbon/carbon composite materials exhibit non-homogeneous distribution of ceramic particles, leading to heterogeneity in mechanical properties and reduced service life, making renovation difficult.
Innovation Solution
A manufacturing method involving controlled viscosity of the impregnation solution to ensure homogeneous distribution of ceramic fillers, using sol-gel or colloidal dispersion with additives to maintain viscosity between 12 and 700 mPa s, followed by drying and heat treatment to achieve uniform ceramic particle distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ceramic particles are introduced to improve mechanical properties, then wear resistance is improved, but distribution homogeneity deteriorates
Solution Approach 1:
The patent changes the physical-chemical parameters of the impregnation solution, specifically controlling viscosity within the range of 12-700 mPa·s and adjusting ceramic particle concentration (3-15% by mass). These parameter changes ensure optimal flow characteristics during impregnation while maintaining homogeneous distribution of ceramic particles throughout the carbon preform, resolving the contradiction between wear resistance improvement and distribution homogeneity.
Solution Approach 2:
The patent ensures that the impregnation solution penetrates uniformly throughout the entire volume of the carbon preform, achieving consistent ceramic particle distribution in all regions (core and periphery). This local quality control through optimized viscosity and concentration ensures homogeneous reinforcement throughout the material, preventing the heterogeneity that would otherwise occur during drying.
2Ease of manufacture
If ceramic particles are concentrated at edges during drying, then manufacturing simplicity is maintained, but material heterogeneity increases
Solution Approach 1:
The patent applies preliminary action by optimizing the viscosity of the impregnation solution before the drying process begins. By controlling viscosity to 12-700 mPa·s and adjusting ceramic concentration to 3-15% by mass, the solution achieves proper penetration and distribution of ceramic particles throughout the preform before drying occurs. This preliminary optimization prevents the harmful concentration gradient that would otherwise form during drying, maintaining homogeneity without complicating the manufacturing process.
3Device complexity
If impregnation solution viscosity is not controlled, then process complexity is reduced, but particle distribution homogeneity deteriorates
Solution Approach 1:
The patent introduces control of the viscosity parameter of the impregnation solution, maintaining it within 12-700 mPa·s, and adjusts ceramic particle concentration to 3-15% by mass. These parameter changes are implemented through straightforward formulation adjustments rather than complex process equipment, achieving homogeneous particle distribution while keeping the manufacturing process relatively simple and industrially viable.
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
Results in a carbon/carbon composite material with homogeneous properties throughout its life, enabling effective renovation and extended service life.
Implementation Method 1
the impregnation of the partially densified blank with an impregnation solution including ceramic precursors or ceramic particles
Implementation Method 2
the drying of the impregnated blank
Data Source
AI summary
Method for manufacturing a part made from carbon/carbon composite material, comprising:the formation of a carbonaceous preform,partial densification of the preform by a pyrocarbon matrix thus forming a partially densified blank,the impregnation of the partially densified blank with an impregnation solution including ceramic particles or ceramic precursors, andthe drying of the impregnated blank.Furthermore, the viscosity of the dispersion or impregnation solution is controlled in order to control the homogeneity of the distribution of the ceramic particles in the part of the impregnated composite material during drying.