Fugitive PVB Core Inserts for Complex CMC Cooling Channels
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Solution Overview
Problem
Current methods for creating cooling structures in ceramic matrix composite (CMC) components are expensive and limited in flexibility, unable to form complex shapes or non-line of sight features, and do not efficiently enhance cooling efficiency.
Innovation Solution
Incorporating polyvinyl butyral (PVB) core inserts into CMC preforms, which are then removed through heat treatment to create internal cavities, allowing for complex cooling channels and structures, and densifying the preform to form a ceramic matrix composite component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If drilling and machining holes, pockets or channels into surfaces are used to create cooling structures, then cooling channels can be formed, but the manufacturing cost increases and manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by embedding the cooling channel geometry directly into the mold cavity before the CMC manufacturing process. This allows the cooling structures to be formed during the initial component fabrication rather than requiring subsequent drilling, machining, or plate attachment operations, thereby reducing manufacturing cost and complexity while maintaining precision
Solution Approach 2:
The patent uses a mold cavity as an intermediary tool that defines the cooling channel geometry. The mold cavity acts as a mediator that transfers the desired cooling structure shape directly into the CMC component during manufacturing, eliminating the need for complex post-processing operations
2Manufacturing precision
If drilling and machining holes, pockets or channels into surfaces are used to create cooling structures, then cooling channels can be formed, but the device complexity increases
Solution Approach 1:
The cooling channel geometry is preliminarily defined in the mold cavity, allowing structures to be formed during initial component fabrication rather than requiring complex post-processing operations like drilling, machining, or plate attachment
Solution Approach 2:
The patent merges the cooling structure formation with the main CMC component fabrication process. By integrating the mold cavity approach, the cooling channels are created simultaneously with the component itself, combining multiple operations into one and reducing overall manufacturing complexity
3Manufacturing precision
If mandrel during layup is used which is subsequently removed leaving a hollow cavity, then internal cavities can be formed, but the manufacturing cost increases
Solution Approach 1:
The patent uses preliminary action by embedding the cooling channel geometry directly into the mold cavity before the CMC manufacturing process, allowing internal cavities to be formed during initial fabrication rather than requiring mandrel insertion and subsequent removal operations
Solution Approach 2:
The mold cavity serves as an intermediary that directly defines the internal cavity geometry during manufacturing, eliminating the need for separate mandrel materials and their subsequent removal, thereby reducing manufacturing cost
4Manufacturing precision
If conventional manufacturing techniques are used, then cooling structures can be created, but flexibility in creating complex internal structures is limited
Solution Approach 1:
The cooling channel geometry is preliminarily defined in the mold cavity, enabling complex internal structures to be formed directly during component fabrication without being constrained by line-of-sight requirements of drilling or machining operations
Solution Approach 2:
The patent applies local quality by allowing different regions of the CMC component to have different properties - the mold cavity defines specific local geometries for cooling channels while the rest of the component maintains its standard CMC structure, enabling complex localized features
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
PVB core inserts enable the formation of cost-effective, complex cooling channels within CMCs, improving heat distribution and reducing thermal stress, while being compatible with CMC materials and manufacturing processes.
Implementation Method 1
subjecting the preform with the one or more integrated polymer core inserts to a heat treatment to remove the one or more polymer core inserts
Implementation Method 2
subjecting the preform with the one or more integrated polymer core inserts to a heat treatment to remove the one or more polymer core inserts
Implementation Method 3
densifying the preform to form a ceramic matrix composite component with the one or more internal cavities
Data Source
AI summary
The preparation of ceramic matrix composite (CMCs) is disclosed in which a ceramic matrix composite (CMC) preform is made with one or more integrated polymer core inserts made of a fugitive material containing polyvinyl butyral. The preform with integrated polymer core inserts to a heat treatment to remove the one or more polymer core inserts (e.g., by melting or burning). Removal of the polymer core inserts forms one or more internal cavities within the composite, which can then be subjected to densification.