Ceramic Structure Rework via Hole Injection
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Solution Overview
Problem
Ceramic structures with multiple layers, such as those used in spacecraft and engines, often experience inconsistencies like delamination or de-bonding, requiring costly and time-consuming replacement rather than repair, which can lead to reduced performance and increased downtime.
Innovation Solution
A method involving the formation of holes in the affected area, introduction of a ceramic bonding material under vacuum, and subsequent curing, either at room temperature or with heat, to re-bond layers and restore structural integrity without replacing the entire component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ceramic structures with multiple layers are used in spacecraft and engines, then thermal resistance and thermal protection capabilities are improved, but inconsistencies like delamination or de-bonding occur requiring costly and time-consuming replacement
Solution Approach 1:
The patent applies segmentation by dividing the repair process into discrete steps: forming holes at specific locations, introducing bonding material through those holes, and curing the material. This segmented approach allows targeted repair of delaminated or de-bonded regions without requiring complete component replacement, thereby improving ease of repair while maintaining thermal protection capability.
Solution Approach 2:
The patent uses a ceramic bonding material as an intermediary substance introduced through holes to re-bond delaminated layers or de-bonded facesheets. This bonding material acts as a mediator that restores the structural integrity and thermal protection function of the ceramic structure, avoiding the need for costly and time-consuming replacement of entire components.
2Reliability
If replacement of inconsistent ceramic parts is performed, then structural integrity is restored, but downtime and costs increase
Solution Approach 1:
The patent employs preliminary action by forming holes in the ceramic structure before introducing the bonding material. This preparatory step enables direct injection of bonding material into delaminated or de-bonded regions, restoring structural integrity more quickly than complete replacement. The method also allows for vacuum application to remove air and ensure proper bonding material distribution, further reducing repair time.
Solution Approach 2:
The patent extracts the problematic air and contaminants from delaminated regions by applying a vacuum through the formed holes before introducing the bonding material. This extraction process ensures proper bonding and structural integrity restoration without requiring complete component removal or replacement, thereby reducing downtime significantly.
3Reliability
If replacement of ceramic components is performed, then performance is maintained, but costs and resource consumption increase
Solution Approach 1:
The patent applies local quality by targeting the bonding material specifically to delaminated or de-bonded regions through precisely formed holes, rather than replacing entire components. This localized repair approach maintains the thermal protection performance and structural integrity of the affected areas while consuming minimal bonding material, avoiding the excessive material consumption associated with complete component replacement.
Solution Approach 2:
The patent recovers and restores the functionality of existing ceramic structures by re-bonding delaminated layers or de-bonded facesheets using bonding material introduced through holes. Instead of discarding and replacing entire components, this approach recovers the service life of existing parts, reducing material consumption and resource waste while maintaining performance.
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 allows for quick and cost-effective repair of ceramic structures, reducing downtime and the need for new parts by re-bonding layers, thus extending the operational life of vehicles and equipment.
Implementation Method 1
A ceramic bonding material is introduced into the number of holes formed in the portion of the ceramic structure. The ceramic bonding material is cured in the portion of the ceramic structure.
Data Source
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AI summary
A method for reworking a ceramic structure. A number of holes are formed in a portion of the ceramic structure in which a rework of the ceramic structure is desired. The ceramic structure has a plurality of layers in the portion in which the rework is desired. A ceramic bonding material is introduced into the number of holes formed in the portion of the ceramic structure. The ceramic bonding material is cured in the portion of the ceramic structure.