Method for drying an impregnated blank and associated manufacturing method
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Solution Overview
Problem
Existing methods for manufacturing carbon/carbon composite parts with ceramic fillers face challenges in achieving a homogeneous distribution of particles, leading to variability in tribological properties and wear patterns over the part's lifespan.
Innovation Solution
A drying process for carbon/carbon composite blanks impregnated with a sol-gel solution, utilizing controlled gas circulation and desaturation to limit solvent evaporation, promoting gelation and reducing macromolecule mobility, resulting in a uniform distribution of ceramic grains.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the blank is impregnated with a sol-gel solution containing ceramic particles, then the tribological properties are improved, but the particles are not homogeneously distributed within the blank
Solution Approach 1:
The patent applies preliminary action by performing gelation before drying. The sol-gel solution is allowed to gel within the carbon blank during a controlled heating phase, forming a gel matrix that traps ceramic particles in place. This preliminary gelation prevents particle migration that would otherwise occur during subsequent drying, ensuring homogeneous distribution throughout the blank.
Solution Approach 2:
The patent utilizes parameter changes by controlling temperature and gas circulation conditions during different process stages. During gelation, temperature is controlled and gas circulation is limited to prevent solvent evaporation and particle migration. During drying, gas circulation is activated to remove solvent while the already-formed gel structure maintains particle homogeneity.
2Productivity
If gas circulation is activated during drying, then solvent evaporation is enhanced, but particle distribution becomes non-uniform due to macromolecule mobility
Solution Approach 1:
The patent performs gelation as a preliminary action before activating gas circulation for drying. The gelation step creates a stable gel network that immobilizes ceramic particles and macromolecules. Only after this preliminary gelation is complete is gas circulation activated, ensuring that enhanced solvent evaporation does not cause particle migration or non-uniform distribution.
Solution Approach 2:
The patent employs periodic action by dividing the process into distinct sequential stages: first a gelation phase with limited gas circulation, then a drying phase with activated gas circulation. This periodic control of gas circulation conditions allows the system to achieve both homogeneous particle distribution (during gelation) and efficient solvent removal (during drying).
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 process ensures a uniform distribution of ceramic grains, minimizing charge gradients and enhancing the consistency of tribological properties across the part's surface and core, thereby reducing wear variability.
Implementation Method 1
gelation of the solution so as to form a gel within the blank disposed in the chamber by heating the chamber
Implementation Method 2
drying of the gel within the blank by heating, the circulation means and the desaturation means being activated, so as to allow the circulation and desaturation of the gas in solvent
Implementation Method 3
the circulation means and the desaturation means being deactivated, so as to limit the circulation and desaturation of the gas in solvent
Data Source
Figure 1
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AI summary
The present invention relates to a method for drying a blank (15) of a part made of a carbon/carbon composite material impregnated with a sol-gel solution comprising a solvent and one or more compounds, in a system (10) comprising: - a chamber (11) for receiving the blank, - gas circulation means (12) for allowing a gas to be circulated between a gas outlet (111) and a gas inlet (112) of the chamber, - gas desaturation means (13) for desaturating the gas in a solvent, the method comprising: - gelling the solution to form a gel by heating the chamber, the circulation and desaturation means being deactivated to restrict circulation and desaturation, - drying the gel by heating, the circulation and desaturation means being activated to enable circulation and desaturation. Drawing_references_to_be_translated: