Composite Fabrication for Rocket Nozzles
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Solution Overview
Problem
Rocket nozzle materials face challenges in achieving thermal performance, structural strength, ease of manufacture, reduced fabrication cost, and minimizing waste, particularly in satisfying strength requirements, especially in the thickness direction.
Innovation Solution
A composite material fabrication method involving the stacking of fiber layers and binders to form a three-dimensional structure with mesh openings, filled with fiber filaments and additional binders, utilizing 3D printing for automation and high-performance continuous fibers, followed by heat treatment and densification processes to enhance structural integrity and reduce manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional monolithic materials are used for rocket nozzles, then thermal performance can be achieved, but structural strength and ease of manufacture deteriorate
Solution Approach 1:
The patent employs a composite material structure consisting of fiber layers (e.g., carbon fiber, ceramic fiber) combined with binder materials. This composite approach enables the rocket nozzle to simultaneously achieve high-temperature resistance through ceramic/carbon fiber layers and improved manufacturability through the binder matrix that facilitates layered fabrication processes.
Solution Approach 2:
The rocket nozzle is divided into multiple fiber layers stacked in sequence, with each layer serving specific functional requirements. This segmentation allows independent optimization of each layer for thermal performance while enabling modular manufacturing and assembly processes.
2Strength
If high strength requirements are met through material selection, then structural strength is improved, but fabrication cost and complexity worsen
Solution Approach 1:
The fiber layers are pre-formed and stacked in the desired configuration before final curing and densification. This preliminary arrangement of reinforcement fibers allows the complex strong structure to be achieved through systematic layering rather than complex monolithic forming processes.
Solution Approach 2:
The patent utilizes changes in material parameters during processing - the binder transitions from a workable state during layering to a cured state providing structural integrity. This parameter change enables the fiber layers to be arranged in complex configurations before final strength development through curing.
3Ease of manufacture
If conventional fabrication methods are used, then manufacturing process is simple, but manufacturing precision and structural integrity worsen
Solution Approach 1:
The fabrication process is segmented into distinct stages: layering fiber layers with binders, curing the binder to form a green body, and subsequent densification. This segmentation enables precise control at each stage, achieving high manufacturing precision through cumulative refinement rather than single-step processing.
4Strength
If material density is increased for strength, then structural strength is improved, but manufacturing complexity and waste generation worsen
Solution Approach 1:
The composite structure utilizes a controlled porous architecture where fiber layers are stacked with interspersed binder layers, creating a hierarchical pore structure. This porous configuration provides sufficient structural strength through fiber reinforcement while minimizing material usage compared to dense monolithic structures.
Solution Approach 2:
The composite material system combines high-strength fiber reinforcement with a binder matrix in optimized proportions, achieving high strength-to-weight ratio and reduced material waste compared to conventional monolithic materials that require higher densities for equivalent strength.
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 method results in a composite material with superior structural integrity and reduced manufacturing costs, capable of withstanding severe stresses while minimizing waste and requiring fewer post-machining processes, suitable for applications like rocket nozzles.
Implementation Method 1
stacking a plurality of fiber layers and a first binder and curing the first binder to form a three-dimensional structure with a plurality of mesh openings
Implementation Method 2
followed by heat treatment and densification processes to enhance structural integrity
Data Source
AI summary
A composite material fabrication method includes stacking a plurality of fiber layers and a first binder and curing the first binder to form a three-dimensional structure with a plurality of mesh openings, and filling the plurality of mesh openings with a plurality of fiber filaments of a fiber array and a second binder and curing the second binder. A plurality of first mesh openings of the plurality of mesh openings are connected in a first direction.