Commingled Fiber Preform With Pyrolyzed Paths for Uniform Densification
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Solution Overview
Problem
Existing carbon-carbon manufacturing methods face challenges in achieving uniform gas infiltration and densification due to limited pathways in commingled fiber preforms, leading to components with less than 10% open porosity and suboptimal structural integrity.
Innovation Solution
A commingled fiber preform architecture is developed, utilizing carbon fibers commingled with fusible and fugitive fibers, joined via through thickness reinforcement (TTR), which allows for uniform gas infiltration and densification by creating pathways through pyrolysis of fugitive fibers, forming a carbon matrix.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a dry fabric preform is used in typical carbon-carbon manufacturing, then the preform structure is simple and easy to manufacture, but the gas infiltration is non-uniform and densification is suboptimal
Solution Approach 1:
The patent applies preliminary action by incorporating fugitive fibers and fusible fibers into the preform structure before the densification process. These fibers are pre-positioned to create pathways and facilitate uniform gas infiltration during subsequent pyrolysis and densification steps, ensuring homogeneous densification throughout the preform.
Solution Approach 2:
The patent utilizes porous materials by incorporating fugitive fibers that create porous pathways through the preform structure. During pyrolysis, these fibers decompose to form channels that enable uniform gas flow and infiltration, creating a porous intermediate structure that facilitates homogeneous densification while maintaining preform integrity.
2Quantity of substance
If the preform has limited pathways for gas infiltration, then the structure remains compact and dense, but uniform densification cannot be achieved
Solution Approach 1:
The patent applies segmentation by dividing the preform structure into multiple pathways through the incorporation of fugitive fibers arranged in specific patterns. These fibers create segmented infiltration routes that distribute gas flow throughout the preform, enabling uniform densification while maintaining overall structural compactness.
Solution Approach 2:
The patent uses intermediaries by introducing fusible fibers as mediators between the gas infiltration process and the final densification. These fibers facilitate uniform gas distribution and act as temporary structures that guide the densification process, ensuring homogeneous carbon fiber packing throughout the preform.
3Ease of operation
If fugitive fibers are pyrolyzed to create infiltration pathways, then gas infiltration is improved, but the preform structure experiences temporary weakening
Solution Approach 1:
The patent applies preliminary action by incorporating fusible fibers that provide temporary structural support during the pyrolysis process. These fibers are pre-positioned to maintain preform integrity while the fugitive fibers decompose, creating infiltration pathways without compromising structural strength during the vulnerable pyrolysis stage.
Solution Approach 2:
The patent uses beforehand cushioning by incorporating fusible fibers that act as a protective network during pyrolysis. These fibers provide mechanical support and cushioning to the preform structure while the fugitive fibers decompose, preventing structural collapse and maintaining integrity until the densification process completes.
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 densification and higher open porosity, enhancing structural integrity and strength properties in high-temperature composites, particularly in complex geometries and thick sections.
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 second fabric layer is joined to the at least one first fabric layer via through thickness reinforcement (TTR) using a commingled thread
Data Source
AI summary
A commingled fiber preform is provided. The commingled fiber preform includes at least one first fabric layer and a second fabric layer. The second fabric layer is positioned on top of the at least one first fabric layer. The second fabric layer is joined to the at least one first fabric layer 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 an entirety of the at least one first fabric layer. 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.