Commingled Fiber Preform Architecture for Uniform Gas Densification
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing carbon-carbon manufacturing methods face challenges in achieving uniform gas infiltration and densification due to insufficient pathways in commingled fiber preforms, leading to components with low open porosity and suboptimal strength properties.
Innovation Solution
A commingled fiber preform architecture is developed using carbon, fusible, and fugitive fibers, with through-thickness reinforcement (TTR) to create uniform gas pathways, allowing for uniform densification and high strength properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If dry fabric is used to make a preform, then the preform can be formed into a shaped composite body, but the gas infiltration is non-uniform due to insufficient pathways
Solution Approach 1:
The preform is segmented into multiple fabric layers (first fabric layers and second fabric layer) with through-thickness reinforcement pathways created by commingled threads that penetrate through all layers. This segmentation creates multiple independent gas infiltration pathways, enabling uniform gas distribution throughout the preform thickness while maintaining a manageable structural complexity through systematic layering.
Solution Approach 2:
The invention transitions from planar fabric layers to a three-dimensional architecture by incorporating through-thickness reinforcement (TTR) pathways. The commingled threads extend in the through-thickness direction, creating a multi-dimensional network that provides gas infiltration routes perpendicular to the fabric planes, thereby achieving uniform infiltration without excessive complexity.
2Manufacturing precision
If through thickness reinforcement is added to create gas pathways, then gas infiltration uniformity improves, but the preform structure becomes more complex
Solution Approach 1:
The invention merges the reinforcement function with the gas infiltration pathway function by using commingled threads that contain both structural fibers (e.g., carbon fibers) and fugitive fibers. This merging allows the same element to provide both mechanical strength and create infiltration pathways when the fugitive fibers are removed, thereby improving densification uniformity without proportionally increasing structural complexity.
Solution Approach 2:
Fugitive fibers serve as an intermediary material within the commingled threads. These temporary elements facilitate gas infiltration pathways during processing, and are subsequently removed to create the final infiltration channels. This intermediary approach enables uniform densification while keeping the permanent preform structure relatively simple.
3Ease of manufacture
If commingled fibers with fusible and fugitive fibers are used, then infiltration pathways are created, but the manufacturing process becomes more complex
Solution Approach 1:
The invention utilizes parameter changes in the fiber materials, specifically the fusible fibers that melt or decompose at processing temperatures to create infiltration pathways. By changing the physical state of the fusible fibers during processing, the structure transitions from a closed configuration to an open pathway configuration, enabling easy gas infiltration without complex manufacturing steps.
Solution Approach 2:
The fusible fibers undergo phase transitions (melting or decomposition) during the manufacturing process to create infiltration pathways. This phase change automatically generates the required gas flow channels without additional manufacturing complexity, as the structural transformation occurs intrinsically through thermal processing.
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 solution enables uniform gas infiltration and enhanced densification, resulting in high-temperature composite components with improved strength and complex geometry capabilities.
Implementation Method 1
The fugitive fibers are pyrolyzed from the commingled fiber preform to create a path through the thickness for infiltration of fluids
Implementation Method 2
the fusible fibers are pyrolyzed from the commingled fiber preform
Data Source
AI summary
A commingled fiber preform is provided. The commingled fiber preform includes a plurality of first fabric layers and a second fabric layer. The second fabric layer is positioned on top of the plurality of first fabric layers. The second fabric layer is joined to the plurality of first fabric layers via through thickness reinforcement (TTR) using a commingled thread. A transport depth of the TTR penetrates completely through a thickness of the second fabric layer and partially through a thickness of the plurality of first fabric layers. The commingled thread comprises carbon fibers commingled with fugitive fibers. The fugitive fibers are pyrolyzed from the commingled fiber preform to create a path through the thickness for infiltration of fluids.