Fiber Coating Frame Geometry for Uniform CMC Fiber 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 interact only with the fibers and not the frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fibers are wrapped around a frame for coating, then the fibers can be held in position during the coating process, but contact between the fibers and the frame creates low or uncoated regions
Solution Approach 1:
The frame is vibrated during the coating process to prevent the fibers from making continuous contact with the frame surface. This vibration causes the fibers to oscillate and remain slightly elevated above the frame, allowing the coating to uniformly deposit on all fiber surfaces without creating uncoated regions at contact points.
2Ease of manufacture
If the frame contacts the fibers during coating, then the fibers are supported, but flaws are introduced in the coating
Solution Approach 1:
Vibration of the frame during coating prevents direct sustained contact between fibers and frame, eliminating the introduction of flaws such as uncoated regions and surface defects in the coating layer.
3Productivity
If reactants flow over the frame and fibers, then coating can be applied, but the frame interferes with reactant interaction with fibers
Solution Approach 1:
The vibration of the frame causes the fibers to oscillate and remain elevated above the frame surface, creating optimal spacing that allows reactants to freely access and interact with all fiber surfaces. This ensures thorough and uniform coating deposition without frame interference.
4Shape
If tension is applied to fibers during wrapping, then fibers are held taut on the frame, but contact regions develop where coating is insufficient
Solution Approach 1:
Vibration during the coating process counteracts the tension-induced contact between fibers and frame, causing the fibers to oscillate and maintain consistent spacing from the frame. This ensures uniform coating coverage even under tension, eliminating uncoated regions that would otherwise form at contact points.
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 consistent coating and improving the mechanical properties of CMC components by eliminating flaws introduced during the coating process.
Implementation Method 1
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 interact only with the fibers and not the frame
Data Source
AI summary
Frame for use in coating a reinforcing fiber are provided. The frame includes a first frame end having a first cross-sectional shape. The first cross-sectional shape has one or more contact locations that are spaced apart from each other. The reinforcing fiber contacts the first frame end at the one or more contact locations. Methods are also provided for coating such a fiber.