Ceramic Core Composite with Infiltrated Fiber Reinforcement
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Solution Overview
Problem
Existing methods for manufacturing composite components, such as those with ceramic fiber reinforcement, often require removable cores that cannot be reused, leading to increased costs and time, and struggle to integrate functionalities like cooling channels and sensors effectively.
Innovation Solution
A method involving a ceramic core that remains integral to the component, surrounded by an outer fiber reinforcement infiltrated with a carbonaceous or polymeric material, which is pyrolyzed to form a high-strength ceramic fiber composite, allowing for cost-effective and quick production while enabling functionalities like insulation, cooling, and sensor integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a removable core is used in composite component manufacturing, then the component can be formed with complex geometries, but the core cannot be reused and manufacturing time and cost increase
Solution Approach 1:
Instead of using a removable core that is discarded after forming the composite, the patent inverts the approach by using a reusable ceramic core that remains in the final component. The fiber reinforcement is applied over this permanent core, eliminating the need for core removal and enabling rapid recycling of the core for subsequent manufacturing cycles.
Solution Approach 2:
The patent implements core recovery by designing the ceramic core to remain in the final component and be reused in subsequent manufacturing cycles. The core is recovered from the composite structure and can be recycled for producing new components, significantly reducing waste and manufacturing time compared to disposable cores.
2Shape
If a removable core is used in composite component manufacturing, then the component can be formed with complex geometries, but manufacturing cost increases
Solution Approach 1:
The ceramic core is designed to be recovered and reused in subsequent manufacturing cycles, eliminating the need to discard and replace cores. This recovery approach significantly reduces material costs and manufacturing expenses compared to using disposable removable cores.
Solution Approach 2:
The patent inverts the traditional approach by making the core permanent rather than removable. This inversion allows the core to be retained in the final component and reused, thereby reducing the overall manufacturing cost associated with core replacement and waste disposal.
3Strength
If traditional composite manufacturing methods are used, then fiber reinforcement can be applied, but functionalities like cooling channels and sensors cannot be integrated
Solution Approach 1:
The ceramic core is designed with multi-functionality, serving as both the structural support for fiber reinforcement application and as an integrated platform for cooling channels and sensors. This universal design allows the core to perform multiple functions simultaneously, enabling functional integration without compromising fiber reinforcement strength.
Solution Approach 2:
The patent implements nesting by incorporating cooling channels and sensors within the ceramic core structure. The core acts as a container that holds these functional elements, allowing them to be integrated into the composite component without adding external complexity or compromising the fiber reinforcement layer.
4Strength
If high temperature pyrolysis is applied to form ceramic matrix, then high strength component is achieved, but energy consumption increases
Solution Approach 1:
The fiber reinforcement is impregnated with pyrolyzable matrix material (such as polymer or carbonaceous material) before application to the ceramic core. This preliminary impregnation ensures that the matrix is already in place and positioned correctly, allowing the subsequent pyrolysis to occur more efficiently and with lower energy input compared to applying matrix material after the core is formed.
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 approach results in a cost-effective and rapid production of high-strength ceramic fiber composite components that can integrate various functionalities, such as insulation and cooling, without the need for removable cores, and provides enhanced structural integrity and durability.
Implementation Method 1
pyrolyzing the infiltrated fiber reinforcement or the ceramic core with the infiltrated fiber reinforcement
Implementation Method 2
the heat treatment causes the polymeric material to be converted to carbon
Implementation Method 3
to protect the fiber reinforcement from oxidation and/or to achieve gas-tightness
Data Source
Figure 1~2
Figure 3
AI summary
A method for producing a ceramic fiber composite component (100) is described. The method comprises providing (310) a ceramic core (110) that forms the interior of the finished ceramic fiber composite component (100) and applying (320) an outer fiber reinforcement (120) to the ceramic core (110). Simultaneously or subsequently, the method may include infiltrating (330) the fiber reinforcement (120) with a carbon-containing or polymeric material (125) and pyrolyzing (340) the infiltrated fiber reinforcement (120) or the ceramic core (110) with the infiltrated fiber reinforcement (120). Furthermore, a composite component with a ceramic core and an outer fiber reinforcement infiltrated with a pyrolyzed carbon-containing or polymeric material is described. Infiltration (315, 330) can be carried out before application (320).