Seal Plate Channel Layout for Uniform CVI Preform Densification
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Solution Overview
Problem
Conventional chemical vapor infiltration and deposition (CVI/CVD) systems face challenges in achieving uniform densification and microstructure formation across the thickness of porous structures, leading to impaired creation of uniformly densified materials, particularly in carbon/carbon brake disks.
Innovation Solution
A seal plate with a plurality of channels is introduced, featuring first and second channels that extend through the plate, with specific geometries and alignments to facilitate uniform gas distribution and pressure gradients, allowing for enhanced material densification and processing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional CVI/CVD systems are used, then the processing can be completed, but the densification is not uniform across the thickness of the porous structure
Solution Approach 1:
The seal plate is segmented into multiple channels (first channels and second channels) that extend through the plate thickness. These channels are arranged in specific patterns with varying widths to divide and distribute gas flow uniformly across different regions of the porous structure, addressing the non-uniform densification problem.
Solution Approach 2:
The channels are designed with varying widths where the first width at the first end differs from the second width at the second end. This local variation in channel geometry creates different gas flow rates and pressure distributions in different regions, enabling uniform densification across the entire porous structure thickness.
2Productivity
If conventional seal plates are used, then the structure is simple, but the processing time is long
Solution Approach 1:
The seal plate channels are pre-configured with specific width variations and arrangements before the CVI/CVD process. This preliminary design of the gas distribution system ensures optimal gas flow and pressure distribution from the start, enabling faster and more efficient densification without requiring complex real-time adjustments during processing.
3Manufacturing precision
If uniform densification is achieved through improved gas distribution, then the manufacturing precision improves, but the device complexity increases
Solution Approach 1:
The seal plate with its configured channels serves multiple functions simultaneously: it distributes gas uniformly, creates appropriate pressure gradients, and maintains structural integrity. This multi-functionality in a single component achieves uniform microstructure formation without requiring multiple separate complex systems.
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 seal plate design promotes uniform densification and processing efficiency by ensuring consistent gas flow and pressure distribution, addressing the uniformity issues in CVI/CVD systems and enhancing the mechanical strength and uniformity of the resulting materials.
Implementation Method 1
a pressure differential driving the gas mixture into the porous structures. The gas enters into the porous structures, driven by pressure gradients
Implementation Method 2
undergoes a reaction such as thermal decomposition, hydrogen reduction, co-reduction, oxidation, carbonization, or nitridation to deposit a binding matrix
Implementation Method 3
Any appropriate material or combination of materials may be utilized for the seal plate, including without limitation Carbon/Carbon (C/C), Silicon Carbide (SiC) or other refractory type materials that can withstand CVD temperatures
Data Source
AI summary
A seal plate disposable between a pair of preforms for chemical vapor infiltration is disclosed. The seal plate may include a plurality of first channels that extend completely through the seal plate and that are located between an inner annulus and outer annulus of the seal plate. The seal plate may further include a plurality of second channels that also extend completely through the seal plate and that are located also between an inner annulus and outer annulus. The first channels may differ from the second channels in at least one respect (e.g., the first channels may be of a different width than the second channels). The first channels may provide an inlet for the chemical vapor infiltration of the preform, while the second channels may provide an outlet for the chemical vapor infiltration of the preform.