Functionally Graded Carbon Composite Seals for Erosion Resistance
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Solution Overview
Problem
Existing seals lack simultaneous high elasticity, erosion resistance, and thermal stability, limiting their application in harsh environments, while metal-to-metal seals are ineffective in sealing rough surfaces due to low elasticity and conformability.
Innovation Solution
Functionally graded carbon composite articles with varying carbon to binder weight ratios and reinforcing agents, providing gradients in properties like elasticity, corrosion resistance, and hardness, enhancing erosion resistance and thermal stability while maintaining mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If elastomers are used for seals, then elasticity and conformability are improved, but erosion resistance and thermal stability deteriorate
Solution Approach 1:
The patent uses composite materials by combining elastomer particles within a graphite matrix. The elastomer provides elasticity and conformability for sealing rough surfaces, while the graphite matrix provides erosion resistance and thermal stability. This composite structure resolves the contradiction by integrating the advantages of both materials.
Solution Approach 2:
The patent applies local quality by creating a functionally graded material where the distribution of elastomer particles and graphite varies through the thickness of the seal. The inner surface near the sealing interface has higher elastomer content for conformability, while the outer regions have higher graphite content for erosion resistance, optimizing both properties in their respective locations.
2Reliability
If metals are used for seals, then erosion resistance and thermal stability are improved, but elasticity and conformability deteriorate
Solution Approach 1:
The patent uses composite materials by combining elastomer particles within a graphite matrix. The elastomer provides elasticity and conformability for sealing rough surfaces, while the graphite matrix provides erosion resistance and thermal stability. This composite structure resolves the contradiction by integrating the advantages of both materials.
3Reliability
If functionally graded structure is implemented, then simultaneous high elasticity and erosion resistance are achieved, but manufacturing complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the seal into distinct functional zones: an inner elastomer-rich layer for sealing, a transitional zone, and an outer graphite-rich layer for erosion resistance. This segmentation allows each zone to be optimized independently while simplifying the overall manufacturing process through layered construction.
Solution Approach 2:
The patent uses parameter changes by varying the concentration of elastomer particles and graphite throughout the seal thickness. The functionally graded structure is achieved by controlling the spatial distribution of these components, with elastomer content decreasing and graphite content increasing from the inner to outer surfaces, optimizing both elasticity and erosion resistance.
Data Source
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AI summary
An article comprises a first member comprising a first carbon composite; and a second member disposed on the first member and comprising a second carbon composite and a reinforcing agent, wherein the second member has a gradient in the weight ratio of the second carbon composite to the reinforcing agent, and wherein the first member has one or more of the following properties different than those of the second member: elasticity; corrosion resistance; erosion resistance; or hardness.