Method for electrospinning of an ultra-high temperature composite structure
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Solution Overview
Problem
Manufacturing ultra-high temperature ceramic matrix composite structures that can withstand extreme conditions such as high temperatures and pressures is challenging due to difficulties in achieving sufficient density in complex shapes using conventional methods.
Innovation Solution
An electrospinning system with a spinneret and collector biased with different DC voltages, aided by a magnetic field adjusted by magnets, is used to form nanofibers from polymeric precursors, which are then pyrolyzed and carbothermally or borothermally reduced to create dense, high-temperature ceramic composite structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing methods are used to form composite structures, then the manufacturing process is simple, but the density of the composite material in complex shapes is insufficient
Solution Approach 1:
The patent replaces conventional mechanical manufacturing methods with electrospinning technology. The electrospinning system uses electrical fields to draw and deposit nanofibers, forming dense composite structures without mechanical contact. This substitution enables precise control over fiber placement and density, achieving high-density composite materials in complex shapes that cannot be obtained through traditional mechanical means.
Solution Approach 2:
The patent utilizes changes in electrical parameters (voltage, electric field strength) to control the electrospinning process. By adjusting the voltage applied to the spinneret and collector, the system can precisely control fiber deposition density, fiber orientation, and layer formation. This parameter control enables achievement of high density in complex geometries while maintaining manufacturing feasibility.
2Manufacturing precision
If electrospinning is used to form nanofibers, then the alignment and density of nanofibers are enhanced, but the device complexity increases due to addition of magnets and voltage biasing system
Solution Approach 1:
The electrospinning system is divided into distinct functional modules: the spinneret assembly (with voltage biasing), the magnetic field generation system (separate magnets), and the collector. This segmentation allows each component to be optimized independently and facilitates easier maintenance and operation despite the overall system complexity. The magnetic field is generated by separate magnets positioned around the flowpath, not integrated into the spinneret, further simplifying the overall system architecture.
Solution Approach 2:
The patent introduces magnetic fields as an intermediary mechanism to control nanofiber alignment during electrospinning. Rather than directly controlling fiber orientation through complex mechanical means, the magnetic field acts as an intermediary that guides and aligns the nanofibers as they are deposited on the collector. This intermediary approach achieves high alignment precision while keeping the control system relatively simple.
3Adaptability or versatility
If multiple polymeric precursors are dispensed coaxially, then the versatility of the electrospinning system is improved, but the device complexity increases
Solution Approach 1:
The spinneret is designed with universal compatibility to handle multiple polymeric precursors simultaneously through coaxial dispensing. The spinneret configuration allows different polymer solutions to be delivered through concentric channels, enabling the formation of core-shell or multi-layer nanofibers. This multi-functional design allows a single spinneret to perform multiple functions (dispensing different materials) without requiring separate spinnerets for each polymer type, thus improving versatility while controlling complexity.
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 enhances the alignment and density of nanofibers, resulting in ultra-high temperature ceramic matrix composite structures with improved thermal resistance and reduced porosity, suitable for extreme conditions like those encountered in hypersonic vehicles and reusable space systems.
Implementation Method 1
A first spinneret disposed at a first end of a flowpath and biased at a first DC voltage... The first spinneret is configured to dispense a first polymeric precursor into the flowpath forming a first plurality of nanofibers. A collector is disposed at a second end of the flowpath and spaced from the first spinneret along the flowpath. The collector is biased at a second DC voltage different than the first DC voltage
Implementation Method 2
A plurality of magnets having a magnetic field are disposed about the flowpath between the first spinneret and the collector. The plurality of magnets is configured to adjust the magnetic field so as to change a direction of movement of the first plurality of nanofibers along the flowpath
Implementation Method 3
The first layer of the plurality of nanofibers deposited on the collector is pyrolyzed with a rapid thermal processing assembly by applying a thermal energy to the first layer of the plurality of nanofibers
Data Source
AI summary
A method for forming an ultra-high temperature (UHT) composite structure includes dispensing a polymeric precursor with a spinneret biased at a first DC voltage; forming a plurality of nanofibers from the polymeric precursor; receiving the plurality of nanofibers with a collector biased at a second DC voltage different than the first DC voltage; and changing a direction of movement of the plurality of nanofibers between the spinneret and the collector with a plurality of magnets having a magnetic field by adjusting the magnetic field.