Reinforcing Fiber Coating Frame for Uniform CMC Coverage
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Solution Overview
Problem
Existing methods for coating fibers in ceramic matrix composites (CMCs) often result in low or uncoated regions, leading to flaws and reduced mechanical properties in the composite components.
Innovation Solution
The use of frames with specific geometries and a semi-static coating process to minimize contact between fibers and the frame, ensuring thorough coating by reducing tension and optimizing frame-end shapes to allow reactants to coat the fibers uniformly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fibers are coated using conventional frame contact methods, then the coating process can be completed, but low or uncoated regions are formed leading to flaws in the composite components
Solution Approach 1:
The frame is designed to be movable relative to the fiber bundle, allowing dynamic adjustment during the coating process. This movement enables the frame to maintain optimal contact with the fibers while accommodating variations in fiber diameter and coating thickness, preventing uncoated regions and ensuring uniform coating coverage throughout the process.
Solution Approach 2:
The frame incorporates localized contact points or regions with specific geometric features that are optimized for different zones of the fiber bundle. This allows different parts of the frame to apply appropriate local pressure or contact characteristics to ensure complete coating coverage while preventing defects in critical areas.
2Ease of manufacture
If frame contact geometry is simplified for ease of manufacture, then the coating process becomes easier to implement, but coating coverage is reduced creating uncoated regions
Solution Approach 1:
The frame is divided into multiple segments or modular components, each with simplified geometric features that are easy to manufacture. These segments can be assembled to form the complete frame structure, maintaining both manufacturing simplicity and the necessary geometric complexity for adequate fiber contact and coating coverage.
Solution Approach 2:
The frame design incorporates universal geometric features that serve multiple functions: providing structural support, maintaining contact with fibers, and facilitating coating material distribution. This multi-functionality reduces the need for complex specialized components while ensuring adequate coating coverage across different fiber bundle configurations.
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 approach minimizes low or uncoated regions, ensuring the composite components meet material specifications and maintain structural integrity by eliminating flaws introduced during the coating process.
Implementation Method 1
The frame includes a first frame end having a first cross-sectional shape, wherein the first cross-sectional shape includes a first contact location spaced apart from an adjacent second contact location by a separation length. The reinforcing fiber contacts the first frame end at the first contact location and the second contact location such that a minimal length of the reinforcing fiber is within a minimum distance from the frame.
Implementation Method 2
inserting the frame into a reactor; initiating a flow of reactants into the reactor
Data Source
AI summary
A system for coating reinforcing fiber of a composite component is provided, The system includes a frame including at least one contact location for contacting the reinforcing fiber and a movement mechanism including an actuator. The movement mechanism is operably coupled to the frame to induce movement of the reinforcing fiber relative to the frame. Methods are also provided for coating such a fiber.