Ceramic-Particle Composite Layup for Higher Heat Capacity
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Solution Overview
Problem
Existing methods face challenges in incorporating boron or boron carbide materials into carbon fiber structures for C/C and CMC components, limiting the size and amount that can be incorporated, which hinders the development of heat sinks with increased heat capacity for aircraft brakes.
Innovation Solution
A method involving the deposition of boron carbide powder between textile layers of a fibrous preform, followed by densification using chemical vapor infiltration and silicon melt infiltration, to create a composite component with enhanced boron carbide content and increased specific heat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If boron or boron carbide materials are incorporated into carbon fiber structures, then heat capacity is improved, but the size and amount of high heat capacity materials that can be incorporated is limited
Solution Approach 1:
The patent segments the carbon fiber structure into multiple textile layers with interspersed ceramic particle layers between them. This segmentation allows ceramic particles to be distributed throughout the volume of the composite component, significantly increasing the total volume of high heat capacity materials that can be incorporated while maintaining structural integrity.
Solution Approach 2:
The patent implements a nested structure where ceramic particle layers are positioned between and integrated with multiple textile layers. The textile layers contain and support the ceramic particles, creating a nested arrangement that maximizes the volume of ceramic materials within the overall composite component structure.
2Use of energy by moving object
If the volume of ceramic particles is increased, then heat capacity is improved, but porosity increases and density decreases
Solution Approach 1:
The patent applies local quality by creating distinct regions with different properties: dense textile layers provide structural integrity while interspersed ceramic particle layers provide high heat capacity. This local differentiation allows the composite to achieve high overall specific heat while maintaining adequate density through the alternating dense and particle-rich zones.
Solution Approach 2:
The patent creates a composite material structure combining textile layers and ceramic particle layers. This composite approach allows the material to exhibit properties of both components: the structural strength and density of the textile layers combined with the high heat capacity of the ceramic particles, achieving a balance between specific heat and density.
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
The method allows for greater volumes of boron carbide to be included, reducing porosity and increasing the density and specific heat of the composite component, enhancing its thermal performance.
Implementation Method 1
densification using chemical vapor infiltration
Implementation Method 2
silicon melt infiltration, reducing porosity and increasing the density
Data Source
Figure 1
Figure 2~3
Figure 4A~4B
AI summary
A fiber reinforced composite component may include interleaved textile layers and ceramic particle layers coated with matrix material. The fiber reinforced composite component may be fabricated by forming (250) a fibrous preform and densifying the fibrous preform (262). The fibrous preform may be fabricated by forming (272) a first ceramic particle layer over a first textile layer, disposing (274) a second textile layer over the first ceramic particle layer, forming (276) a second ceramic particle layer over the second textile layer, and disposing (278) a third textile layer over the second ceramic particle layer.