Partially Densified Filtration Layer for Refractory Ceramic Composite Injection
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Solution Overview
Problem
The removal of filtration elements in the production of composite materials can be difficult, especially in complex geometries, leading to degradation of the fibrous texture and challenges in designing filters that accommodate both mould geometry and fibrous texture.
Innovation Solution
A process involving a filtration layer made of partially densified refractory ceramic fibres, integrated into the composite material part, which allows for pressure injection and drainage of a slurry, retaining ceramic particles and eliminating the need for a separate filtration element, facilitating the production of composite parts with complex shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rigid filter element is used for drainage, then filtration of solvent is achieved, but removal from fibrous texture is difficult and may degrade the texture
Solution Approach 1:
The filtration function is merged with the fibrous texture itself by using the same refractory ceramic fibres for both the texture and the filtration layer. The filtration layer is made from the same material as the fibrous texture, eliminating the need for a separate rigid filter element that would need to be removed later.
Solution Approach 2:
The filtration layer is partially densified through heat treatment at lower temperature than the final sintering step. This partial densification provides adequate filtration capability while maintaining flexibility and integration with the fibrous texture, avoiding the degradation issues associated with rigid filter elements.
2Reliability
If a rigid filter element is used, then solvent drainage is effective, but accommodation of complex mould geometry and fibrous texture is difficult
Solution Approach 1:
The filtration layer is made from flexible fibrous material rather than rigid structure. This flexible fibrous filtration layer can conform to complex mould geometries and the three-dimensional structure of the fibrous texture, enabling effective drainage in parts with complex shapes.
Solution Approach 2:
The filtration layer is constructed from refractory ceramic fibres that are compatible with the fibrous texture material. This composite approach allows the filtration layer to integrate seamlessly with the fibrous texture while maintaining the ability to drain solvent effectively in complex geometries.
3Ease of manufacture
If filtration layer is integrated into the part, then removal issues are eliminated, but additional material is present in the final product
Solution Approach 1:
The filtration layer is positioned locally at the evacuation port interface where drainage is needed. It is not distributed throughout the entire part, but concentrated where it performs its filtration function, minimizing the additional material volume while maintaining process simplification benefits.
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 simplifies the production of composite materials by integrating a filtration layer that is not rigid, allowing for complex geometries and eliminating the issues of filtration element removal, resulting in a densified composite material with a homogeneous refractory ceramic matrix.
Implementation Method 1
drainage by the filtration layer of the solvent of the slurry having passed through the fibrous texture and retention of the refractory ceramic particles within said texture by the filtration layer
Implementation Method 2
the filtration layer comprising a partially densified fibrous structure
Implementation Method 3
heat treatment of the refractory ceramic particles present in the fibrous texture of the preform in order to form a composite material part comprising at least said fibrous texture densified by a refractory ceramic matrix
Data Source
AI summary
A process for manufacturing a composite material part includes formation of a fibrous texture from refractory ceramic fibres, placement of the fibrous texture in a mould with interposition of a filtration layer between the fibrous texture and a discharge port, the filtration layer including a partially densified fibrous structure, pressure injection of a slurry containing a powder of refractory ceramic particles into the fibrous texture, drainage by the filtration layer of the slurry solvent having passed through the fibrous texture and retention of the powder of refractory ceramic particles within the texture by the filtration layer to obtain a fibrous preform including the fibrous texture filled with refractory ceramic particles and the filtration layer, heat treatment of the refractory ceramic particles present in the fibrous texture of the preform to form a composite material part including the fibrous texture densified by a refractory ceramic matrix and the filtration layer.