MULTI-LAYER CERAMIC COMPOSITE POROUS STRUCTURE

• US 20160348586A1
• Filed: 08/11/2016
• Published: 12/01/2016
• Est. Priority Date: 12/30/2010
• Status: Abandoned Application

• Current Assignee: Rolls-Royce North American Technologies, Inc. (Rolls-Royce Holdings Plc)
• Original Assignee: Rolls-Royce North American Technologies, Inc. (Rolls-Royce Holdings Plc)
• Inventors: Uskert, Richard Christopher, Freeman, Ted Joseph, Thomas, David John, Lane, Jay
• Application Number:
  US15/234,101
• Publication Number:
  US 20160348586A1
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B32B 18/00 Layered products essentially comprising ceramics, e.g. refractory products
• CPC Class Codes: B32B 2250/03 3 layers
• CPC Class Codes: B32B 2250/20 All layers being fibrous or filamentary
• CPC Class Codes: B32B 2250/40 Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
• CPC Class Codes: B32B 2250/42 Alternating layers, e.g. ABAB(C), AABBAABB(C)
• CPC Class Codes: B32B 2260/04 Impregnation, embedding, or binder material
• CPC Class Codes: B32B 2266/04 Inorganic
• CPC Class Codes: B32B 2266/06 Open cell foam
• CPC Class Codes: B32B 2307/306 Resistant to heat
• CPC Class Codes: B32B 2307/724 Permeability to gases, adsorption
• CPC Class Codes: B32B 2307/726 Permeability to liquids, absorption
• CPC Class Codes: B32B 2603/00 Vanes, blades, propellers, rotors with blades
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/22 characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed layer formed of natural mineral fibres or particles next to a foam layer B32B19/047, next to a layer made of particles B32B19/048, or next to a fibrous or filamentary layer B32B19/06; paper layer or cardboard layer next to a paper layer or cardboard layer B32B29/005, next to a foam layer B32B29/007, next to a fibrous or filamentary layer B32B29/02, or next to a particulate layer B32B29/04
• CPC Class Codes: B32B 5/24 one layer being a fibrous or filamentary layer
• CPC Class Codes: B32B 5/245 another layer next to it being a foam layer
• CPC Class Codes: B32B 5/26 another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: B32B 9/005 comprising one layer of ceramic material, e.g. porcelain, ceramic tile layered products with at least two ceramic layers composed mainly of ceramic B32B18/00
• CPC Class Codes: B32B 9/007 comprising carbon, e.g. graphite, composite carbon
• CPC Class Codes: B32B 9/046 of foam
• CPC Class Codes: C04B 2237/04 : Ceramic interlayers
• CPC Class Codes: C04B 2237/32 : Ceramic
• CPC Class Codes: C04B 2237/38 : Fiber or whisker reinforced
• CPC Class Codes: C04B 2237/62 : Forming laminates or joined articles comprising holes, channels or other types of openings
• CPC Class Codes: C04B 37/005 : consisting of glass or ceramic material
• CPC Class Codes: F01D 5/18 : Hollow blades, i.e. blades with cooling or heating channels or cavities structure of hollow blades in general F01D5/147; Heating, heat-insulating or cooling means on blades
• CPC Class Codes: F02C 7/18 : the medium being gaseous, e.g. air F02C7/125 takes precedence
• CPC Class Codes: F05D 2300/6033 : Ceramic matrix composites [CMC]
• CPC Class Codes: F05D 2300/612 : Foam
• CPC Class Codes: Y10T 156/10 : Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 428/24331 : including nonapertured component
• CPC Class Codes: Y10T 428/24997 : Of metal-containing material
• CPC Class Codes: Y10T 442/335 : Plural fabric layers

Abstract

An article of manufacture includes a first ceramic matrix composite (CMC) sheet having a number of flow passages therethrough, and a CMC foam layer bonded to the first CMC sheet. The CMC foam layer is an open-cell foam. The article of manufacture includes a second CMC sheet bonded to the CMC foam layer, the second CMC sheet having a thermal and environmental barrier coating and having a number of flow passages therethrough.

Claims

1. A method, comprising:

forming a first ceramic matrix composite (CMC) sheet, and providing a plurality of flow paths therethrough;

rigidizing the first CMC sheet into a component shape;

bonding a shaped, open-cell CMC foam layer to the first CMC sheet;

forming a second CMC sheet;

bonding the second CMC sheet to the foam layer thereby forming a component structure; and

curing the component structure.

2. The method of claim 1, further comprising providing a plurality of flow paths through the second CMC sheet before the bonding the second CMC sheet.

3. The method of claim 2, wherein providing the plurality of flow paths through the second CMC sheet comprises perforating the second CMC sheet.

4. The method of claim 3, further comprising applying a thermal and environmental barrier coating to the second CMC sheet before the perforating.

5. The method of claim 1, further comprising providing the plurality of flow paths through the first CMC sheet and the second CMC sheet by perforating the CMC sheets.

6. The method of claim 5, further comprising staggering the perforations of the first CMC sheet and the second CMC sheet.

7. The method of claim 5, further comprising aligning the perforations of the first CMC sheet and the second CMC sheet.

8. The method of claim 1, further comprising:

determining a component strength requirement;

in response to the component strength requirement, determining at least one design parameter selected from the parameters comprising;

a number of layers each layer comprising a CMC foam layer interposed between two CMC sheets, a thickness of each of the CMC sheets, a density of the CMC foam layer, and a geometric shape of the component structure; and

conforming the component structure to the at least one design parameter.

9. The method of claim 1, further comprising:

determining a component cooling capability requirement;

in response to the component cooling capability requirement, determining at least one design parameter selected from the parameters comprising;

a sizing of the flow paths, a shape factor of the flow paths, an alignment value of the flow paths, a thermal and environmental barrier coating design, and a density of the CMC foam layer; and

conforming the component structure to the at least one design parameter.

10. A method, comprising:

providing a multi-layer ceramic matrix composite (CMC) component comprising two opposing CMC sheets and a CMC open-cell foam layer therebetween;

exposing one of the CMC sheets directly to high-temperature turbine engine gases; and

flowing a coolant fluid through the CMC open-cell foam layer and through a plurality of flow passages defined by at least one of the CMC sheets.

11. The method of claim 10, wherein the exposing comprises flowing turbine engine combustion gases in contact with the one of the CMC sheets.

12. The method of claim 11, further comprising rotating the multi-layer CMC component during the exposing.

13. The method of claim 10, wherein the flowing comprises providing a first heat transfer value from the multi-layer CMC component to the coolant fluid that is lower than a second heat transfer value, the second heat transfer value comprising a required heat transfer for a metal component.

14. A method, comprising:

forming a first ceramic matrix composite (CMC) sheet, and providing a plurality of flow paths therethrough;

rigidizing the first CMC sheet into a component shape;

bonding a shaped, open-cell CMC foam layer to the first CMC sheet;

forming a second CMC sheet;

providing a plurality of flow passages through the second CMC sheet;

bonding the second CMC sheet to the foam layer after the providing a plurality of flow passages step, thereby forming a component structure; and

curing the component structure.

15. The method of claim 14, further comprising applying a thermal and environmental barrier coating to the second CMC sheet before the providing a plurality of flow passages step.

16. The method of claim 14, further comprising providing the plurality of flow passages through the first CMC sheet prior the bonding a shaped, open-cell CMC foam layer to the first CMC sheet step.

17. The method of claim 16, wherein the flow passages of the first CMC sheet are staggered relative to the flow passages of the second CMC sheet.

18. The method of claim 16, wherein the flow passages of the first CMC sheet are aligned with the flow passages of the second CMC sheet.

19. The method of claim 14, further comprising rigidizing the second CMC sheet prior to the providing a plurality of flow passages through the second CMC sheet step.