Composite Sheet Manufacturing Using Random Fiber Binder Slurry
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Solution Overview
Problem
Current composite fabrication methods using random fibers face challenges in forming small and thin articles due to the difficulty of flexing and forming thick felt materials, and high-temperature processing limits random fiber orientation in ceramic matrix composites.
Innovation Solution
A method involving a container with a binder and randomly oriented fibers, where the fibers are coated and cured to form a composite sheet, which is then interlocked within the binder, allowing for the creation of composite components with uniform strength in all planar directions by using a mold and depositing a matrix material into voids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If thick felt material is used to form composite, then fiber density is improved, but flexibility and ability to form small thin articles deteriorates
Solution Approach 1:
The patent uses a thin film binder layer to hold random fibers together, replacing thick felt materials. This thin film approach maintains fiber density while providing the flexibility needed to form small and thin articles, directly resolving the contradiction between fiber density and flexibility.
Solution Approach 2:
The patent creates a composite structure combining random fibers with a binder matrix. This composite material approach allows the fibers to be held together in a flexible matrix, enabling both high fiber density and the flexibility required for forming complex geometries.
2Strength
If high temperature matrix media is added during fabrication, then ceramic matrix composite strength is improved, but random fiber orientation capability deteriorates
Solution Approach 1:
The patent applies random fibers to the mold surface before adding the high temperature matrix media. This preliminary action ensures that random fiber orientation is established and locked in place before the matrix is poured, allowing both high temperature processing and precise fiber orientation control to coexist.
Solution Approach 2:
The patent uses a binder material as an intermediary layer between the random fibers and the high temperature matrix media. This binder acts as a mediator that maintains fiber position and orientation during the high temperature processing, enabling both fiber orientation control and ceramic matrix strength.
3Quantity of substance
If spray based process is used for random fibers, then fiber distribution is improved, but mold complexity and processing difficulty increases
Solution Approach 1:
The patent uses a simple dip-coating process where the mold is dipped into a fiber-binder slurry. This self-service approach allows the mold to automatically acquire uniformly distributed random fibers through the dipping action, eliminating the need for complex spray systems while achieving excellent fiber distribution.
Solution Approach 2:
The patent employs a liquid slurry-based process where fibers are suspended in a binder solution. The liquid medium allows for uniform fiber distribution through simple dip-coating, replacing complex pneumatic spray systems with a simpler hydraulic/liquid-based approach that achieves the same fiber distribution goal.
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 method provides higher precision in fiber positioning, reduces material costs, and achieves uniform strength and thickness in composite components, preventing distortions and excessive trimming.
Implementation Method 1
A plurality of randomly oriented fibers are added to the binder. The container is subjected to motion to coat the plurality of randomly oriented fibers with the binder to form a slurry.
Implementation Method 2
The binder and coated plurality of randomly oriented fibers are cured to form a composite sheet. The plurality of randomly oriented fibers are interlocked within the binder.
Implementation Method 3
The composite sheets and mold are heated to a burn-out temperature, wherein heating vaporizes the binder and creates a green ceramic component comprising the plurality of randomly oriented fibers joined by carbon bonds
Implementation Method 4
A matrix material is deposited in the voids and along the plurality of randomly oriented fibers forming the composite component.
Data Source
AI summary
A method of making a composite sheet, a method of making composite component and a composite component are provided. The method of making a composite sheet includes providing a container, adding a binder to the container, adding a plurality of randomly oriented fibers to the binder in the container, and subjecting the container to motion to coat the plurality of randomly oriented fibers with the binder. The method includes curing the binder and coated plurality of randomly oriented fibers to form a composite sheet. The plurality of randomly oriented fibers of the composite sheet are interlocked within the binder. The composite has uniform strength in all planar directions.