PROCESS OF PRODUCING A COMPOSITE COMPONENT AND INTERMEDIATE PRODUCT THEREOF
First Claim
1. A process of producing a composite component comprising a matrix material reinforced with a three-dimensional preform, the process comprising the steps of:
- producing a first set of tows in which each tow contains a plurality of substantially parallel filaments, has a predetermined cross-sectional shape, and is embedded within a temporary matrix material formed of a material that is not the matrix material or a precursor of the matrix material;
producing at least a second set of tows in which each tow contains a plurality of substantially parallel filaments; and
thenfabricating the three-dimensional preform to comprise the first and second sets of tows, in which the tows of the second set are transverse to the tows of the first set, adjacent tows of the second set are spaced apart to define interstitial regions therebetween having a cross-sectional shape, and the predetermined cross-sectional shapes of the tows of the first set are substantially congruent to the cross-sectional shapes of the interstitial regions so as to substantially fill the interstitial regions.
1 Assignment
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Accused Products
Abstract
A preform architecture and process for producing composite materials, and particularly CMC components. The process entails producing a composite component having a matrix material reinforced with a three-dimensional preform. The process includes producing first and second sets of tows containing filaments. Each tow of the first set has a predetermined cross-sectional shape and is embedded within a temporary matrix material formed of a material that is not the matrix material or a precursor of the matrix material. The preform is then fabricated from the first and second sets of tows, in which the second set of tows are transverse to the first set of tows, adjacent tows of the second set are spaced apart to define interstitial regions therebetween, and the cross-sectional shapes of the first set of tows are substantially congruent to the cross-sectional shapes of the interstitial regions so as to substantially fill the interstitial regions.
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Citations
20 Claims
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1. A process of producing a composite component comprising a matrix material reinforced with a three-dimensional preform, the process comprising the steps of:
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producing a first set of tows in which each tow contains a plurality of substantially parallel filaments, has a predetermined cross-sectional shape, and is embedded within a temporary matrix material formed of a material that is not the matrix material or a precursor of the matrix material; producing at least a second set of tows in which each tow contains a plurality of substantially parallel filaments; and
thenfabricating the three-dimensional preform to comprise the first and second sets of tows, in which the tows of the second set are transverse to the tows of the first set, adjacent tows of the second set are spaced apart to define interstitial regions therebetween having a cross-sectional shape, and the predetermined cross-sectional shapes of the tows of the first set are substantially congruent to the cross-sectional shapes of the interstitial regions so as to substantially fill the interstitial regions. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
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14. A process of producing a gas turbine engine component comprising a ceramic matrix material reinforced with a three-dimensional preform, the process comprising the steps of:
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producing a first set of tows in which each tow contains a plurality of substantially parallel ceramic filaments has a predetermined cross-sectional shape, and is embedded within a temporary matrix material formed of a polymeric material that is not the ceramic matrix material or a precursor of the ceramic matrix material; producing at least a second set of tows in which each tow contains a plurality of substantially parallel filaments; fabricating the three-dimensional preform to comprise the first and second sets of tows, in which the first set of tows are static tows, the second set of tows are dynamic tows and transverse to the tows of the first set, adjacent tows of the second set are spaced apart to define interstitial regions therebetween having a cross-sectional shape, and the predetermined cross-sectional shapes of the tows of the first set are substantially congruent to the cross-sectional shapes of the interstitial regions so as to substantially fill the interstitial regions; heating the preform to remove the temporary matrix material on the first set of tows so as to yield substantially uniform spacing between the first and second sets of tows; and infiltrating the spacing between the first and second sets of tows to form the gas turbine engine component, wherein the preform is within the ceramic matrix material and the temporary matrix material is removed during the heating of the preform without leaving any amount of residue on the tows of the first set that would reduce the mechanical properties of the gas turbine engine component. - View Dependent Claims (15, 16, 17, 18, 19, 20)
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Specification