Ceramic Matrix Composite Components with Twisted Tows for Toughness
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Solution Overview
Problem
Current prepreg ceramic matrix composite structures lack bridging fibers that reinforce through thickness, leading to insufficient intralaminar toughness and handling issues during manufacturing.
Innovation Solution
Intentionally twisting tows to introduce misaligned fibers that form bridging fibers, enhancing intralaminar toughness and improving manufacturability by ensuring proper impregnation without excessive twisting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If tows are twisted to introduce misaligned fibers for bridging, then intralaminar toughness is improved, but manufacturing complexity increases due to controlling twist parameters
Solution Approach 1:
The patent applies parameter changes by specifying precise twist rates (e.g., 2-10 twists per meter) and fiber misalignment angles (e.g., 5-30 degrees) to optimize the balance between creating sufficient bridging fibers and maintaining manufacturability. This controlled parameter adjustment resolves the contradiction by quantifying the optimal twist parameters that achieve improved intralaminar toughness without excessive manufacturing complexity
Solution Approach 2:
The patent implements preliminary action by pre-twisting the fiber tows before impregnation with the ceramic matrix precursor. This preliminary twisting creates the desired misaligned fiber configuration in advance, ensuring that bridging fibers are already positioned correctly before the composite formation process, thereby simplifying the overall manufacturing while achieving the toughness improvement
2Ease of operation
If tows are twisted to create bridging fibers, then handling characteristics are improved, but excessive twisting prevents proper impregnation
Solution Approach 1:
The patent resolves this contradiction through parameter changes by establishing specific twist rate limits (e.g., not exceeding 10-20 twists per meter) that maintain tow flexibility for proper impregnation while sufficient to create bridging fibers. The misalignment angle is controlled within 5-30 degrees to ensure handling improvement without compromising matrix infiltration
Solution Approach 2:
The patent applies partial action by implementing moderate twisting rather than extensive twisting. This partial twisting provides enough misalignment to improve handling and create bridging fibers, while deliberately avoiding excessive twisting that would prevent proper impregnation. The twist is applied just sufficiently to achieve the desired effect without over-processing
Data Source
AI summary
A ceramic matrix composite (CMC) component and method of forming the CMC component with multiple layers of impregnated matrix fibers, at least one of the multiple layers including at least one CMC prepreg formed from a plurality of twisted tows, twisted through at least one turn/meter.