Thermal Processing System for CMC Components
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Solution Overview
Problem
The existing thermal processing systems for composite components, such as ceramic matrix composites (CMCs), are inefficient and costly due to the need for multiple separate thermal systems, which leads to contamination risks, high energy consumption, and potential damage during component transfer, as well as inefficiencies in heating and pressurizing large chambers.
Innovation Solution
A system comprising a thermal system with multiple vessels of standard shape and configuration, a mover device, and a control system that allows for sequential thermal processing of composite components within the same system, enabling compaction, burnout, and densification processes in a single setup, reducing the need for multiple systems and enhancing efficiency by focusing heat and pressure on smaller vessel volumes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate thermal systems are used for different thermal processes, then each process can be performed with dedicated equipment, but the system complexity increases and requires significant floor space
Solution Approach 1:
The patent combines multiple separate thermal systems (autoclave, furnace, melt-infiltration system) into a single integrated thermal processing system. This single system can perform compaction, burnout, and densification processes sequentially within the same chamber, eliminating the need for multiple standalone equipment while maintaining process separation through sequential operation and appropriate atmosphere control.
Solution Approach 2:
The thermal processing system is designed with multi-functionality to perform various thermal processes (compaction, burnout, densification) using a single chamber. The system can adjust operating conditions (temperature, pressure, atmosphere) to accommodate different process requirements, making the equipment universal rather than dedicated to a single function.
2Reliability
If components are moved between different thermal systems, then contamination between processes is prevented, but the transfer time increases and potential for damage occurs
Solution Approach 1:
By integrating multiple thermal processes within a single chamber, the patent eliminates the need to physically move components between separate systems. The chamber serves as a continuous processing environment where components undergo compaction, burnout, and densification without removal, thus preventing contamination while eliminating transfer time and damage risks.
Solution Approach 2:
The system dynamically adjusts operating conditions (temperature, pressure, atmosphere composition) during the processing sequence to accommodate different process requirements within the same chamber. This dynamic control allows the single chamber to maintain process separation through parameter changes rather than physical separation.
3Volume of moving object
If large chambers are used in thermal systems, then sufficient space is available for processing, but the energy required to heat and pressurize the chamber increases significantly
Solution Approach 1:
The patent segments the processing space by using multiple smaller vessels within a single chamber rather than one large chamber. Each vessel contains the component and requires less energy to heat and pressurize. The chamber acts as a containment structure while the actual processing occurs in smaller, energy-efficient vessels.
Solution Approach 2:
The system employs a nested configuration where smaller processing vessels are placed inside the larger chamber. This allows the chamber to provide structural containment and atmospheric control while the smaller vessels perform the actual thermal processing with reduced energy requirements, as they have smaller volume-to-surface-area ratios.
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 streamlines the thermal processing of composite components, reducing energy consumption, minimizing contamination risks, and enhancing processing efficiency by allowing all thermal processes to be performed within a single system, thereby saving time and resources.
Implementation Method 1
heating and pressurizing large chambers
Implementation Method 2
compaction, burnout, and densification processes
Data Source
AI summary
Systems and methods for thermally processing composite components are provided. In one exemplary aspect, a system includes a thermal system, a mover device, and a control system. The system also includes a plurality of vessels in which one or more components may be placed. The vessels are similarly shaped and configured. A vessel containing the one or more components therein may be mounted into a chamber defined by the thermal system during thermal processing. The thermal system and vessels include features that allow components to be thermally processed, e.g., compacted, burnt-out, and densified via a melt-infiltration process, a polymer impregnation and pyrolyzing process, or a chemical vapor infiltration process. utilizing the same thermal system and common vessel design. The control system may control the thermal system and mover device to automate thermal processing of the composite components.