Spiked Roller Tow Separation for CMC Fabric Infiltration
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Solution Overview
Problem
In the processing of ceramic matrix composites, large voids between tows in woven CMC systems lead to defects that diminish interlaminar strength, as existing methods fail to effectively infiltrate the matrix within and around tows, resulting in reduced composite strength.
Innovation Solution
A method involving a roller with spiked protrusions is used to separate tows within a woven ceramic fabric by impinging the protrusions into the fabric, increasing the number of tows per unit area and facilitating even infiltration of ceramic particles during densification, thereby enhancing matrix formation and interlaminar strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional woven fabric processing is used, then the fabric structure is simple and easy to manufacture, but large voids exist between tows leading to defects that diminish interlaminar strength
Solution Approach 1:
The invention applies segmentation by dividing the fabric processing into distinct stages: initial tensioning, spiked protrusion penetration for tow separation, and controlled relaxation. This multi-stage approach systematically addresses the large voids between tows by mechanically separating them in a controlled manner, improving matrix infiltration and interlaminar strength
Solution Approach 2:
The invention employs preliminary action by pre-tensioning the woven fabric before applying the spiked protrusions. This pre-tensioning step prepares the fabric structure to receive the separation treatment, ensuring that the spiked protrusions can effectively penetrate and separate tows without causing fabric distortion or damage
2Manufacturing precision
If tow size is reduced to reduce pore size, then infiltration surface area increases, but the number of tows per unit area becomes excessively high complicating processing
Solution Approach 1:
The invention applies parameter changes by systematically adjusting the spiked protrusion dimensions (diameter, length, spacing) and the tensioning parameters during processing. These parameter optimizations allow effective tow separation and pore size control without excessively increasing the number of tows per unit area, maintaining processability while achieving uniform infiltration
3Reliability
If spiked protrusions are used to separate tows, then matrix infiltration is improved, but the processing equipment complexity increases
Solution Approach 1:
The invention applies universality by designing the spiked protrusion roller to perform multiple functions simultaneously: it separates tows, controls fabric tension distribution, and guides the fabric through the processing line. This multi-functional design improves infiltration quality without proportionally increasing equipment complexity, as one component achieves multiple objectives
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 method results in a more uniform pore distribution and improved ceramic particle infiltration, leading to enhanced interlaminar strength and robust matrix formation in ceramic matrix composites, suitable for aerospace, maritime, and industrial applications.
Implementation Method 1
separating filaments within tows of the woven fabric tape by penetration of at least one of the spiked protrusions into the woven fabric tape, such that filaments within various tows of the woven fabric tape are pushed apart
Data Source
AI summary
A method of preparing a woven fabric material for use in a ceramic matrix composite includes securing a woven fabric tape in tension across a roller, the roller having an outer surface with a plurality of spiked protrusions extending radially therefrom, each of the plurality of spiked protrusions having a diameter between 10 microns and 500 microns. The method further includes passing the woven fabric along the roller, such that the roller rotates with the passing of the woven fabric tape, thereby impinging the spiked protrusions into the woven fabric tape, and separating filaments within tows of the woven fabric tape by penetration of at least one of the spiked protrusions into the woven fabric tape, such that filaments within various tows of the woven fabric tape are pushed apart to form a separated woven fabric tape with a greater number of tows per unit area than the woven fabric tape.