CMC Core Inserts for Complex Internal Cooling Cavities
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Solution Overview
Problem
Current methods for creating cooling structures in ceramic matrix composite (CMC) components are expensive, limited in flexibility, and unable to form complex shapes or optimize coolant flow, leading to inefficient heat transfer and stress due to thermal gradients.
Innovation Solution
Incorporating polyvinyl butyral (PVB) core inserts with flow modification elements into CMC preforms, which are then removed via heat treatment to create internal cavities, allowing for complex cooling circuits and optimized fluid flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional drilling and machining methods are used to create cooling structures, then the manufacturing process is simple and direct, but the cost increases and manufacturing flexibility is limited
Solution Approach 1:
The patent applies preliminary action by incorporating mandrels and flow modification elements into the composite layup before manufacturing. These elements are embedded during the composite formation process, allowing complex cooling structures to be created as integral features rather than requiring post-manufacturing drilling or machining operations.
Solution Approach 2:
The patent implements nesting by placing flow modification elements within the cooling channels during the composite layup process. The mandrels and flow modification elements are nested within the composite structure, allowing multiple functional features to be integrated simultaneously without requiring separate manufacturing steps.
2Ease of manufacture
If traditional line of sight manufacturing techniques are used, then the manufacturing process is straightforward, but the ability to create complex internal structures is limited
Solution Approach 1:
The patent uses preliminary action by pre-positioning mandrels and flow modification elements within the composite layup before final manufacturing. This allows complex three-dimensional cooling structures with internal passages and flow control features to be created without requiring line-of-sight access during manufacturing.
Solution Approach 2:
The patent employs mandrels as intermediary elements that serve as placeholders and structural guides during manufacturing. These mandrels enable the formation of complex internal geometries that would otherwise be inaccessible, allowing coolant passages and flow modification features to be created through the composite structure.
3Ease of manufacture
If traditional cooling structures are implemented, then the basic cooling function is provided, but the ability to optimize coolant flow and reduce leakage is insufficient
Solution Approach 1:
The patent applies local quality by incorporating flow modification elements at specific locations within cooling channels to create localized flow control features. These elements include flow restrictors, deflectors, and distributors positioned at critical locations to optimize coolant distribution and prevent leakage in specific regions.
Solution Approach 2:
The patent utilizes porous flow modification elements that can be integrated into the composite structure to control coolant flow through the cooling channels. These porous elements provide flow restriction and distribution functions while maintaining structural integrity and preventing leakage.
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
Enables cost-effective formation of complex cooling structures within CMC components, enhancing heat distribution and reducing thermal stress by providing flexible, efficient coolant pathways.
Implementation Method 1
subjecting the preform with the one or more integrated polymer core inserts to a heat treatment to remove the base structures of the one or more polymer core inserts
Data Source
AI summary
The preparation of ceramic matrix composite (CMCs) is disclosed in which a ceramic matrix composite (CMC) preform is made with one or more integrated polymer core inserts having a base structure made of a fugitive material comprising polyvinyl butyral (PVB), and one or more flow modification elements made of a non-fugitive material. The preform with integrated polymer core inserts is subjected to a heat treatment to remove the PVB base structure made of the one or more polymer core inserts (e.g., by melting or burning) while retaining the one or more flow modification elements. Removal of the PVB base structure forms one or more internal cavities within the composite with the one or more flow modification elements positioned therein. The preform can then be subjected to densification to form the CMC.