System and 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 that uses a spinneret and collector with a magnetic field to align and deposit polymeric precursors as nanofibers, followed by rapid thermal processing to form a dense three-dimensional composite structure, incorporating a rapid thermal processing assembly for pyrolysis and carbothermal or borothermal reduction to achieve high temperature ceramic materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing methods are used, then the manufacturing process is simple, but the composite material density in complex shapes is insufficient
Solution Approach 1:
The patent replaces conventional mechanical manufacturing methods with electrospinning technology, which uses electrical fields to deposit polymeric precursor nanofibers. This substitution enables precise control over material deposition and achieves high density in complex three-dimensional shapes that cannot be obtained through traditional mechanical processes.
Solution Approach 2:
The patent employs rapid thermal processing with controlled temperature and time parameters to pyrolyze the deposited nanofibers and form dense ceramic matrix composite structures. By optimizing thermal processing parameters, the system achieves high density and structural integrity in complex geometries.
2Manufacturing precision
If electrospinning is used to form nanofibers, then the composite material density improves, but the system complexity increases
Solution Approach 1:
The electrospinning system integrates multiple functions into a unified platform: it deposits nanofibers, aligns them using magnetic fields, and prepares them for rapid thermal processing. This multi-functional integration achieves high nanofiber alignment and density while managing system complexity through coordinated operation of interconnected components.
Solution Approach 2:
The patent uses magnetic fields as an intermediary mechanism to align nanofibers during deposition. The magnetic field acts as a mediator that controls fiber orientation without direct mechanical contact, enabling precise alignment while maintaining system elegance and managing complexity.
3Reliability
If rapid thermal processing is applied, then the ceramic material properties improve, but the energy consumption increases
Solution Approach 1:
The rapid thermal processing employs periodic heating and cooling cycles to pyrolyze the polymeric precursor and form ceramic materials. By using controlled periodic thermal action, the system achieves high reliability in thermal and electrical properties while minimizing total energy consumption through efficient cycle management.
Solution Approach 2:
The patent utilizes phase transitions during rapid thermal processing, where the polymeric precursor transforms into ceramic material through controlled pyrolysis. This phase transition approach enables achieving superior material properties with reduced energy input compared to conventional slow heating methods.
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 system effectively forms ultra-high temperature ceramic matrix composites with improved density and alignment, enhancing their thermal and electrical properties, suitable for applications in hypersonic vehicles and reusable space systems.
Implementation Method 1
a spinneret and collector with a magnetic field to align and deposit polymeric precursors as nanofibers
Implementation Method 2
pyrolyzing the plurality of nanofibers
Implementation Method 3
carbothermal or borothermal reduction to achieve high temperature ceramic materials
Implementation Method 4
applying a thermal energy to a first layer of the plurality of nanofibers deposited on the collector
Data Source
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AI summary
A method for forming an ultra-high temperature (UHT) composite structure includes dispensing a polymeric precursor (20) with a spinneret (12) biased at a first DC voltage; forming a plurality of nanofibers (26) from the polymeric precursor (20); receiving the plurality of nanofibers (26) with a collector (16) biased at a second DC voltage different than the first DC voltage; and changing a direction of movement of the plurality of nanofibers (26) between the spinneret (12) and the collector (16) with a plurality of magnets (28) having a magnetic field by adjusting the magnetic field.