Multi-Pile Plate Tooling for Uniform CVI Densification

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Solution Overview

Problem

Existing chemical vapor infiltration (CVI) methods for densifying porous annular substrates face challenges in achieving uniform gas distribution and reducing densification gradients between substrates, especially when stacks of varying heights are processed.

Innovation Solution

The method involves forming individual modules with support plates and gas inlet openings, where each module is stacked to allow gas circulation between them, and using deformable annular seals and sealing rings to enhance gas tightness and compensate for height differences between stacks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional support plates with aligned openings are used for multiple stacks, then the device structure is simple, but gas distribution is non-uniform and densification gradients occur between substrates

Engineering Contradiction:

Improvedensification uniformityVSAvoidtooling structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The tooling is divided into individual modules, each handling a single stack independently. Each module has its own support plate with gas inlet opening, seal, and cover plate, allowing independent gas flow control for each stack while maintaining overall system functionality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Each individual module is equipped with localized sealing elements (seal and cover plate) specific to its stack, enabling precise control of gas distribution at each stack location. This local customization ensures uniform gas flow and densification for each stack while accommodating height variations.

Inventive Principle:

Principle #3Local quality

2Productivity

If stacks of varying heights are processed together, then the loading capacity is maximized, but sealing becomes difficult and gas leaks occur

Engineering Contradiction:

Improveloading capacityVSAvoidsealing effectiveness

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The seal is designed as a deformable element that can dynamically adapt to height variations between different stacks. The cover plate of each module can be positioned at different heights and sealed effectively against the deformable seal, accommodating stacks of varying heights while preventing gas leaks.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

A deformable seal (flexible element) is used instead of rigid sealing structures. This flexible seal can deform to match the actual height of each stack, ensuring effective sealing even when stacks have different heights, thereby maintaining gas tightness while maximizing loading capacity.

Inventive Principle:

Principle #30Flexible shells and thin films

3Manufacturing precision

If individual modules with deformable seals are used for each stack, then gas distribution is improved and sealing is enhanced, but the device complexity increases

Engineering Contradiction:

Improvegas distribution uniformityVSAvoidnumber of components

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The individual modules are designed as universal, interchangeable units that can be used for any stack regardless of height. Each module integrates multiple functions (support, sealing, gas distribution) into a single standardized component that can be replicated and reconfigured for different loading scenarios.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 improves gas distribution within the densification furnace, reduces densification gradients, and maintains or increases the loading capacity of the furnace, while ensuring effective sealing to prevent gas leaks.

Implementation Method 1

The infiltration conditions, especially the composition and flow rate of the gas phase, and the temperature and pressure in the chamber, are chosen to allow diffusion of the gas phase within the accessible internal porosity of the substrates so that the desired material is deposited therein

Methodology Applied

Scientific EffectDiffusion: Diffusion

Implementation Method 2

The densification of porous substrates by chemical vapor infiltration (CVI) consists of placing the annular preforms in a reaction chamber of an infiltration installation and admitting into the chamber a gas phase, one or more constituents of which form a precursor of the matrix material to be deposited within the substrates

Methodology Applied

Scientific EffectChemical Vapour Deposition: Chemical Vapour Deposition

Data Source

PatentUS12313140B2Tooling of multi-pile plates for semi-forced flow

Publication Date: 2025.05.27 SAFRAN LANDING SYSTEMS

AI summary

A method for densifying porous annular substrates having a central passage by chemical vapor infiltration, the method including providing stacks of porous annular substrates, providing a plurality of individual modules including stacks disposed on a support plate having a perforated injection tube each mounted on a gas inlet opening, forming a stack of individual modules, aligning the individual modules of the stack in a sealed manner by means of an annular seal disposed between the injection tubes of a second individual module and the gas inlet openings of a first individual module with which it cooperates, and injecting into the internal volume of each stack of porous annular substrates a gas phase including a gaseous precursor of a matrix material to be deposited within the porosities of the substrates.