Cyanate-Ester Basalt Carbon Composite Heat Exchanger Cover
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current thermal exchanger covers for aircraft engines, made from titanium, face high material and manufacturing costs, are fragile under strong vibrations, and alternative materials like ceramics lack flexibility, while traditional organic resins cannot withstand high temperatures.
Innovation Solution
A composite material process using a Cyanate-Ester resin matrix with layers of basalt and carbon fibers, where carbon fibers are inserted between basalt fiber layers, and a Resin Transfer Molding (RTM) process to create a thermal exchanger cover that is resistant to temperatures between 250-300 °C, reducing fatigue sensitivity and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If titanium is used to manufacture thermal exchanger cover, then temperature resistance is improved, but manufacturing cost increases and fatigue resistance deteriorates
Solution Approach 1:
The patent applies composite materials consisting of basalt fibers reinforced with a cyanate ester resin matrix. This composite structure provides both high temperature resistance (from basalt fibers) and improved fatigue resistance (from the resin matrix), resolving the contradiction between temperature resistance and fatigue resistance in titanium components.
2Temperature
If ceramics are used to withstand high temperature, then temperature holding is improved, but flexibility deteriorates causing cracks and breakages
Solution Approach 1:
The patent uses basalt fiber reinforced cyanate ester composite materials that combine the high temperature stability of basalt fibers with the flexibility and toughness of the resin matrix, eliminating the brittleness issue of pure ceramic materials while maintaining temperature holding capability.
3Adaptability or versatility
If traditional organic resins are used, then flexibility is improved, but temperature resistance deteriorates
Solution Approach 1:
The patent changes the chemical composition parameters of the resin by selecting cyanate ester, which has superior thermal stability compared to traditional organic resins. This parameter change allows the resin to maintain its flexible properties while withstanding temperatures up to 250-300°C, resolving the temperature resistance limitation of conventional resins.
4Temperature
If titanium is used for thermal exchanger cover, then temperature resistance is improved, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive titanium material with cheaper basalt fiber reinforced cyanate ester composite material. While individual components may have shorter service life, the overall cost reduction in material and manufacturing processes makes this economically viable, resolving the high manufacturing cost issue of titanium components.
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 composite material achieves mechanical resistance and temperature stability, reducing part replacements and manufacturing costs, with a 20% mass reduction compared to metal counterparts, while maintaining structural integrity and thermal efficiency.
Implementation Method 1
a matrix permeates the reinforcement, made up of a configured resin to withstand temperatures of at least 250 ° C
Implementation Method 2
a reinforcement composed of a plurality of layers of fabric composed of basalt fibers... the reinforcement composed of a plurality of layers of fabric composed of basalt fibers is also composed of at least a layer of fabric composed of carbon fibers
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to the field of heat exchange and concerns a method for producing a composite material for a heat exchanger hood, comprising the following steps carried out successively: - Superposition (101) of a plurality of layers of fabric composed of basalt fibers and/or carbon fibers; - Compaction (102) of the plurality of layers of fabric composed of basalt fibers and/or carbon fibers; - Arrangement (103) of the plurality of compacted layers in a mold; - Molding by resin transfer (104) in the mold of a resin configured to withstand temperatures of at least 250°C until the mold is full; - Heating (105) of the mold to form the composite material; - Demolding (106) of the composite material; - Post-curing (110) of the composite material.