Flexible Ceramic Matrix Composite Seals for Thermal Expansion
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Solution Overview
Problem
Conventional ceramic matrix composites (CMCs) exhibit low flexibility, making them unsuitable for high-temperature applications requiring significant thermal expansion and aerodynamic performance.
Innovation Solution
The method involves joining lamina together with bonded regions and areas of reduced inter-laminar bonding, using bond-inhibiting materials or structures to create CMC structures that are more flexible, allowing for thermal protection systems with enhanced compliance and sealing capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional CMC materials are used in thermal protection systems, then high-temperature resistance is achieved, but flexibility and compliance are insufficient
Solution Approach 1:
The CMC structure is divided into multiple discrete laminae that can move independently relative to each other. The gaps between laminae allow for thermal expansion and flexing while maintaining overall structural integrity at high temperatures.
Solution Approach 2:
Different regions of the CMC structure have different bonding characteristics. Some areas have strong inter-laminar bonds for structural support, while other areas have reduced bonding or gaps to provide flexibility and compliance for thermal expansion.
2Ease of operation
If gaps are created between CMC panels to allow thermal expansion, then flexibility is improved, but sealing capability deteriorates
Solution Approach 1:
The CMC structure incorporates movable joints and gaps that dynamically adjust during thermal cycling. The structure transitions from a rigid configuration at low temperature to a more compliant configuration at high temperature, maintaining sealing capability throughout the range.
Solution Approach 2:
The invention combines CMC materials with complementary materials that have different thermal expansion coefficients and mechanical properties. This composite approach allows the structure to accommodate thermal expansion while maintaining sealing integrity through the synergistic properties of the combined materials.
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
The approach results in CMC structures that can withstand high temperatures and thermal expansion without damage, providing improved flexibility and sealing efficiency in thermal protection systems and other high-temperature applications.
Implementation Method 1
The methods include joining at least two lamina together so as to provide at least one bonded region and at least one region having at least reduced inter-laminar bonds to form a CMC structure. In some embodiments, the lamina may be joined by laying up the lamina with a bond-inhibiting material or structure positioned therebetween and sintering the lamina to form a CMC structure.
Data Source
AI summary
Methods of forming ceramic matrix composite structures include joining at least two lamina together to form a flexible ceramic matrix composite structure. Ceramic matrix composite structures include at least one region of reduced inter-laminar bonding at a selected location between lamina thereof. Thermal protection systems include at least one seal comprising a ceramic matrix composite material and have at least one region of reduced inter-laminar bonding at a selected location between lamina used to form the seal. Methods of forming thermal protection systems include providing one or more such seals between adjacent panels of a thermal protection system.