Ceramic Knit Bulb Seal Structure for High-Temperature Shape Recovery
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Solution Overview
Problem
Current thermal sealing members used in high-temperature applications, such as aircraft structures, face challenges with stiffness, deformation, and marginal thermal resistance, leading to degraded performance and burnout issues due to their multilayer construction and low stainless steel spring tube stiffness.
Innovation Solution
A single-layer ceramic-based knit fabric is developed by concurrently knitting continuous ceramic strands with metal alloy wires, including a load-relieving process aid strand and additional metal alloy wires for tailored stiffness, which are then shaped and heat-treated to form thermal sealing members with improved structural support and thermal resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If multilayer materials including stainless steel spring tube and woven ceramic fabric are used, then thermal barrier capability is provided, but stiffness is low leading to wrinkling and deformations
Solution Approach 1:
The patent uses a composite structure combining ceramic fabric layers with stainless steel mesh layers integrated into a single-knit architecture. The ceramic fabric provides thermal barrier capability while the stainless steel mesh provides structural stiffness and support, resolving the contradiction between thermal protection and structural rigidity.
Solution Approach 2:
The patent merges multiple functional layers (ceramic fabric, stainless steel mesh, binding layers) into a single integrated knit structure that is manufactured as one continuous piece. This integration eliminates the need for separate assembly steps and ensures uniform structural properties throughout the thermal sealing member.
2Reliability
If multilayer materials are integrated by hand, then thermal sealing member is constructed, but fabrication complexity increases and manufacturing efficiency decreases
Solution Approach 1:
The patent replaces manual assembly operations with an automated knitting process that constructs the entire multilayer thermal sealing member in a single continuous manufacturing step. The knitting machine automatically interlaces ceramic fibers, metal wires, and binding threads to form the integrated structure, eliminating hand assembly entirely.
Solution Approach 2:
The patent employs a high-speed knitting process that rapidly constructs the thermal sealing member in one continuous operation rather than through multiple slow assembly steps. This accelerated manufacturing process dramatically improves productivity while maintaining consistent integration quality through automated control.
3Reliability
If bulb seals are repeatedly compressed, then sealing function is maintained, but they do not restore to proper shape and maintain seal
Solution Approach 1:
The patent incorporates elastic elements and flexible knit structures that enable the thermal sealing member to dynamically respond to compression forces. The material can be compressed to maintain sealing contact and then elastically recover its original shape, allowing repeated compression cycles without permanent deformation.
Solution Approach 2:
The patent uses a flexible knit fabric construction that allows the thermal sealing member to deform under compression and then return to its original configuration. The knit structure's inherent flexibility and elasticity enable shape recovery after repeated compression, maintaining sealing effectiveness over time.
4Temperature
If current thermal sealing members are used, then thermal barrier is provided, but thermal resistance is marginal and burnout occurs in short time
Solution Approach 1:
The patent combines ceramic fabric with high-temperature resistant stainless steel mesh in an integrated knit structure. This composite material system provides superior thermal resistance and heat protection compared to single-material constructions, preventing burnout and extending service life in high-temperature environments.
Solution Approach 2:
The patent incorporates multiple protective layers including ceramic fabric and stainless steel mesh that are integrated before the thermal sealing member is put into service. These layers provide preemptive thermal protection and structural reinforcement that prevent burnout and extend the component's operational lifespan.
Data Source
AI summary
Knit fabrics having ceramic strands, thermal protective members formed therefrom and to their methods of construction are disclosed. Methods for fabricating thermal protection using multiple materials which may be concurrently knit are also disclosed. This unique capability to knit high temperature ceramic fibers concurrently with a load-relieving process aid, such as an inorganic or organic material (e.g., metal alloy or polymer), both small diameter wires within the knit as well as large diameter wires which provide structural support and allow for the creation of near net-shape preforms at production level speed. Additionally, ceramic insulation can also be integrated concurrently to provide increased thermal protection.