Redefining Openings in Composite Components
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Solution Overview
Problem
Reinforced ceramic matrix composites (CMCs) with openings pose challenges in repairing surface coatings due to difficulties in maintaining the exact location and configuration of holes or openings during and after repair, leading to inefficiencies in redefining them post-repair.
Innovation Solution
A method involving filling openings with a matrix material that matches the composite's properties, allowing for redefinition of openings without precise alignment, size, or shape, after a new coating is applied, enabling flexible redefinition within a range of distances and configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If openings are kept open during repair, then the original location can be maintained, but the repair process becomes difficult and time-consuming
Solution Approach 1:
The patent applies preliminary action by filling the openings with a material that matches the composite properties before the repair process. This preliminary filling action eliminates the need to maintain precise opening locations during repair, as the filler material provides a uniform surface that can be easily repaired. The openings are subsequently redefined after repair, allowing the repair process to proceed without the complications of maintaining precise opening geometries throughout.
2Ease of repair
If openings are plugged and reopened after repair, then the surface coating can be repaired, but finding the exact original location becomes difficult
Solution Approach 1:
The patent applies the copying principle by creating a surface that replicates the original composite properties using filler material. This copied surface allows the repair process to proceed without needing to know the exact original opening locations, as the filler material provides a uniform baseline. The openings are then redefined based on functional requirements rather than precise original positioning, eliminating the difficulty of locating plugged openings.
3Adaptability or versatility
If openings are redefined after repair, then flexibility in location and configuration is achieved, but precise alignment with original openings becomes impossible
Solution Approach 1:
The patent applies parameter changes by allowing the opening parameters (location, size, shape, orientation) to be modified after repair. The filler material enables this flexibility by providing a uniform surface that doesn't require precise alignment with original openings. The openings can be redefined with different parameters based on current functional requirements, and the filler material ensures that the redefined openings maintain structural integrity similar to the original configuration.
Data Source
Figure 1
Figure 2A
Figure 2B~2D
AI summary
A method (700) of redefining an opening (108) in a composite component (100) comprises filling (704) the opening (108) with a filling material (114), where the opening (108) is defined in a body (102) of the composite component (100) and opens onto a surface (104) defined by the composite component (100), and redefining (712) the opening (108') such that the opening (108') extends into the body (102). Some methods comprise removing (702) an existing coating (106) from the surface (104) of the composite component (100) prior to filling (704) the opening (108) with the filling material (114) and applying (710) a new coating (134) to the surface (104) prior to redefining (712) the opening (108') such that the opening (108') extends through the new coating (134) and into the body (102). An exemplary composite component (100) comprises a body (102), a surface (104) with a coating (134) thereon, an original opening (108) defined through the body (102) and filled with a filling material (114), and a new opening (108') defined through the coating (134) into the body (102); the new opening (108') may be defined at a new location (138) from the original opening (108).