CMC Article Layup with Solvent Diffusion for Stable Consolidation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing methods for forming ceramic matrix composite (CMC) articles face challenges in achieving consistent laminate consolidation during the manufacturing process, particularly due to solvent evaporation during extended layup processes for large articles, which can result in inadequate consolidation and dimensional instability.

Innovation Solution

A system and method involving the use of a solvent supply connected to an enclosure containing the CMC preform, where vacuum pressure and temperature are controlled to establish an equilibrium state for solvent diffusion, ensuring consistent solvent content within the preform and enhancing laminate consolidation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If extended layup process is used for large CMC articles, then complete fiber reinforcement assembly is achieved, but solvent evaporates causing inadequate consolidation and dimensional instability

Engineering Contradiction:

Improvesolvent content in preformVSAvoiddimensional stability of CMC article

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

The patent applies this principle by creating a controlled atmospheric environment within the enclosure that prevents solvent evaporation. The enclosure isolates the preform from ambient conditions, maintaining a stable atmosphere that preserves solvent content throughout the extended layup process, thereby ensuring both complete fiber assembly and dimensional stability.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

Solution Approach 2:

The patent implements parameter changes by controlling temperature and humidity parameters within the enclosure. By adjusting these environmental parameters, the system maintains optimal solvent retention in the preform during extended layup, preventing evaporation-related consolidation issues while allowing complete fiber reinforcement assembly.

Inventive Principle:

Principle #35Parameter changes

2Ease of operation

If solvent is added to provide flexibility during layup, then laminate consolidation is enabled, but solvent loss during extended processing causes inadequate consolidation

Engineering Contradiction:

Improveflexibility of CMC plies during layupVSAvoidsolvent loss during processing

Core Design Contradiction:

Ease of operationVSLoss of substance

Solution Approach 1:

The enclosure creates an inert environmental atmosphere that prevents solvent loss during the extended layup process. This allows the CMC plies to maintain their flexibility and solvent content throughout processing, enabling proper laminate consolidation without the harmful effects of solvent evaporation.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

Solution Approach 2:

The patent ensures continuous solvent retention within the enclosure throughout the extended layup process. By maintaining a controlled environment that continuously preserves solvent content, the system sustains the flexibility needed for ease of operation while preventing solvent loss that would otherwise cause inadequate consolidation.

Inventive Principle:

Principle #20Continuity of useful action

3Ease of manufacture

If ambient evaporation is allowed during layup, then processing is simple, but solvent content becomes unstable causing consolidation issues

Engineering Contradiction:

Improvesimplicity of layup processVSAvoidsolvent content stability in preform

Core Design Contradiction:

Ease of manufactureVSStability of the object's composition

Solution Approach 1:

The patent applies the inert atmosphere principle by enclosing the preform in a controlled environment that eliminates ambient evaporation. This maintains stable solvent content throughout the layup process while keeping the procedure relatively simple, as the enclosure can be implemented as a straightforward atmospheric control system.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

Solution Approach 2:

The system provides self-service by automatically maintaining stable solvent content through the enclosed environment. The enclosure itself serves to prevent evaporation and maintain composition stability without requiring complex active control systems, thereby preserving ease of manufacture while ensuring composition stability.

Inventive Principle:

Principle #25Self-service

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 improves laminate consolidation by maintaining a stable solvent level within the preform, reducing solvent loss to ambient evaporation, and ensuring that the CMC article is formed to specified dimensions, thereby enhancing manufacturing efficiency and product quality.

Implementation Method 1

diffusing the solvent to or from the solvent supply through the plurality of plies

Methodology Applied

Scientific EffectDiffusion: Diffusion

Implementation Method 2

the solvent may evaporate during the extended layup processes used for large articles

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentUS20250289763A1Ceramic matrix composite article manufacturing

Publication Date: 2025.09.18 GENERAL ELECTRIC CO

AI summary

A method for forming a ceramic matrix composite (CMC) article includes laying up a plurality of plies of a CMC material, sealing the plurality of plies in a vacuum enclosure that is in fluid communication with a solvent supply that includes a volume of solvent, and diffusing a solvent to or from the solvent supply through the plurality of plies.