Pre-Ceramic Thermal Barriers for Gas Turbine Composite Heat Protection

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Solution Overview

Problem

Polyimide composites used in gas turbine engines face challenges with mechanical integrity and oxidation resistance due to transient temperature exposures above 600°F, limiting their maximum use temperature.

Innovation Solution

Application of a pre-ceramic thermal barrier layer with low thermal conductivity and high temperature capability, composed of glass or quartz fiber reinforced silicon oxides, to enhance the thermal protection of composite components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If polyimide composite components are used in gas turbine engines, then weight savings and performance durability are achieved, but mechanical integrity and oxidation resistance deteriorate when exposed to transient temperatures above 600°F

Engineering Contradiction:

ImproveweightVSAvoidmechanical integrity

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The patent applies a composite material structure consisting of an organic matrix composite (OMC) base material combined with a pre-ceramic thermal barrier coating layer. This composite structure allows the OMC to provide weight savings while the pre-ceramic layer protects against high-temperature degradation, thereby maintaining mechanical integrity at temperatures above 600°F without sacrificing the weight advantages of OMC materials.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the thermal and protective parameters of the OMC component by applying a pre-ceramic thermal barrier coating. This coating modifies the surface properties to resist oxidation and high-temperature exposure, enabling the component to operate reliably at transient temperatures above 600°F while maintaining the underlying OMC's weight benefits.

Inventive Principle:

Principle #35Parameter changes

2Weight of moving object

If polyimide composite components are used in gas turbine engines, then weight savings and performance durability are achieved, but oxidation resistance deteriorates when exposed to transient temperatures above 600°F

Engineering Contradiction:

ImproveweightVSAvoidoxidation resistance

Core Design Contradiction:

Weight of moving objectVSObject-affected harmful factors

Solution Approach 1:

The patent uses a composite material system where the pre-ceramic thermal barrier coating layer provides oxidation resistance to the OMC component. This layered composite structure allows the lightweight OMC substrate to be protected from oxidative degradation at high temperatures, maintaining both weight savings and oxidation resistance simultaneously.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The pre-ceramic thermal barrier coating acts as an intermediary layer between the OMC component and the harsh high-temperature oxidizing environment. This intermediate layer protects the OMC from direct exposure to oxygen and high temperatures, preventing oxidation while allowing the component to retain its weight advantages.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Temperature

If a thermal barrier coating is applied to increase temperature capability, then maximum use temperature is improved, but device complexity increases

Engineering Contradiction:

Improvemaximum use temperatureVSAvoidcomplexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent applies a pre-ceramic thermal barrier coating to change the thermal parameters of the OMC component, enabling it to withstand transient temperatures above 600°F. This approach increases the maximum use temperature without requiring fundamental redesign of the component architecture, thereby limiting the increase in device complexity to just the addition of the coating layer.

Inventive Principle:

Principle #35Parameter changes

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

The thermal barrier layer increases the maximum operating temperature of composite components by reducing thermal exposure and maintaining mechanical integrity, allowing exposure to temperatures up to 700°F while maintaining low weight and oxidation resistance.

Implementation Method 1

the cured thermal barrier layer is a pre-ceramic layer comprising inorganic matrix containing silicon oxides reinforced with glass or quartz fibers

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

curing the thermal barrier layer before or after the positioning step to produce a cured thermal barrier layer

Methodology Applied

Scientific EffectCuring: Vitrification

Data Source

PatentUS12410729B2Pre-ceramic thermal barrier for gas turbine engine components

Publication Date: 2025.09.09 RTX CORP

AI summary

A gas turbine engine component includes a structural component having a surface, the structural component having an organic matrix composite material; and a cured thermal barrier layer on the surface, wherein the cured thermal barrier layer is a pre-ceramic layer including inorganic matrix containing silicon oxides reinforced with glass or quartz fibers.