GB2541359A

GB2541359A - Ceramic composite component and support assembly

Info

Publication number: GB2541359A
Application number: GB1511222.0A
Authority: GB
Inventors: Henry Nick; Dewhirst Mike
Original assignee: S S Tube Tech Ltd
Current assignee: S S Tube Tech Ltd
Priority date: 2015-06-25
Filing date: 2015-06-25
Publication date: 2017-02-22
Also published as: GB201511222D0

Abstract

A ceramic composite material component 12 such as a ceramic heat shield for a turbocharger is provided with a support arrangement 14 comprising a metallic framework 16 intimately fitted to an exterior of the component 12. The metallic framework may have a crinkle embossed surface to improve contact with the ceramic component. The framework may comprise loop parts 18, 20 which may be tensioned to ensure contact with the ceramic component. The metal may comprise stainless steel, Titanium or Inconel.

Description

CERAMIC COMPOSITE COMPONENT AND SUPPORT ASSEMBLY

This invention relates to a ceramic composite component, and in particular to a support arrangement whereby such a component can be mounted to or otherwise secured to another component, part or structure or the like.

The use of composite materials is becoming increasingly widespread as an alternative to, for example, the use of metallic materials in the manufacture of certain parts or components, for example in the automotive and aerospace industries. The use of composite materials in such applications can allow significant weight savings to be made compared to the use of certain metallic materials, and in addition, depending upon the choice of materials used, the composite material component may be of enhanced strength or other properties compared to the corresponding component manufactured from traditional materials.

Where components are exposed to high temperatures, in use, then the resin-based composite materials in widespread use are unsuitable and instead the materials used in the manufacture of the components are of, for example, suitable ceramic composite materials. Whilst the use of ceramic composite materials allows the components to be capable of withstanding the high temperature conditions in which they are employed, ceramic composite materials are difficult to machine, for example by cutting or drilling, or machining operations carried out thereon run the risk of damage to or failure of the component as the materials typically have a low bending strength and a low level of elongation under tension, and so have a low fracture toughness. Consequently, the attachment of fixings to components to allow the components to be secured to one another and/or mounted in a desired position is difficult, and the level of scrap or wastage where ceramic composite materials are used can be excessive due to failures occurring during such cutting or drilling operations. The use of epoxy-based adhesives to secure the components in position or to one another may be inappropriate in some applications as the high temperature environments in which the components are used exceed the temperatures at which epoxy resins can be used. However, there may be applications in which the use of epoxy-based adhesives for this purpose is possible.

It is an object of the invention to provide a ceramic composite material component with an associated support arrangement in which at least some of the disadvantages associated with known arrangements are overcome or are of reduced effect.

According to the present invention there is provided an assembly comprising a ceramic composite material component and a support arrangement, the support arrangement comprising a support framework intimately fitted to an exterior of the component, the support framework being of a metallic material form.

The framework is conveniently of embossed form, for example of a 'crinkle' embossed material, aiding the shaping of the framework to intimately fit the exterior of the component. However, it will be appreciated that the invention is not restricted in this regard, and that non-embossed arrangements and arrangements with a different embossed pattern may be employed without departing from the scope of the invention.

By way of example, the framework may comprise first and second loop parts of a diameter or dimension smaller than a maximum diameter or dimension of a part of the component, the first loop part being located to one side of the maximum diameter or dimension of the component, and the second loop part being located to the other side of the maximum diameter or dimension, the first and second loop parts being connected to one another by a series of connecting struts. Each of the first and second loop parts conveniently incorporates a tension spring by which respective ends of the loop parts are secured to one another. The loop parts and struts may be welded to one another, for example using an electric resistance seam welding technique. However, it will be appreciated that other techniques may be used to secure the elements of the framework to one another. If desired, the framework may, in some applications, be of one piece construction, but including a releasable tension spring assembly allowing the framework to be fitted around and subsequently intimately secured to the component.

The metallic material conveniently comprises a stainless steel material. However, other materials such as titanium or Inconel may be used without departing from the scope of the invention. It will be appreciated that the materials mentioned above are merely examples of suitable materials. Depending upon the application in which the invention is to be applied, the choice of material used may depend upon whether the material is able to withstand the load and other conditions such as temperature experienced in use.

The invention also relates to a support arrangement of the type described hereinbefore and adapted for use in such an assembly.

The invention will further be described, by way of example, with reference to the accompanying drawings, in which:

Figure 1 is a perspective view illustrating an assembly in accordance with one embodiment of the invention; and

Figures 2 to 4 are views of the assembly of Figure 1 from different angles.

Referring to the accompanying drawings, an assembly 10 is illustrated comprising a ceramic composite material component 12, in this case in the form of a ceramic heat shield for a turbocharger, to which a support 14 in the form of a framework 16 is secured.

The component 12, when viewed from a side as shown in Figure 2, is of generally annular form, but having a generally tangential extension 12a. As is clear from Figures 3 and 4, the component is of curved profile, and so a notional plane 12b in which the generally annular part of the component 12 is of a maximum diameter or dimension can be identified. To each side of the plane 12b, the generally annular part is of reduced diameter.

The framework 16, in this embodiment, is of stainless steel material form, the material conveniently being of 'crinkle' embossed form such that is can readily be deformed to substantially match the shape of the outer surface of the component 12. Whilst a specific material is mentioned hereinbefore, it will be appreciated that the invention is not restricted to the specific material mentioned. Likewise, the material may have a different embossed pattern applied thereto or, indeed, no such embossed pattern may be applied thereto. The framework 16 takes the form of a first loop part 18 and a second loop part 20 which are spaced apart from one another and interconnected with one another by a series of struts 22. The first and second loop parts 18, 20 each form closed loops of generally circular form having a diameter or dimension smaller than the maximum diameter or dimension of the component 12, the first loop part 18 being located to one side of the plane 12b, the second loop part 20 being located to the opposite side of the plane 12b.

In addition to the loop parts 18, 20 and struts 22, the framework also includes an extension region 24 that overlies the generally tangential extension 12a of the component 12.

The loop parts 18, 20, struts 22 and region 24 conveniently take the form of separate elements that are interconnected with one another, for example by being welded to one another. By way of example, they may be laser cut from a flat, suitably embossed stainless steel sheet, and then electric resistance welded to one another to form the framework 16. It is envisaged that the sheet material used in the formation of the framework 16 may be in the region of 0.1mm thickness.

The ends of each loop part 18, 20 are conveniently securable to one another to form respective closed loops by associated releasable spring clip arrangements 26 that each include a resilient part serving to tension the material of the loop regions 18, 20, thereby holding the framework 16 tightly and intimately against the surface of the component 12.

The framework 16 of the support 14 bears intimately against the outer surface of the component 12, the support 14 conforming with the shape of the outer surface of the component 12, and taking the form of an exoskeleton around the component 12. As the support 14 is of stainless steel form, it will be appreciated that fixings (not shown) may be readily affixed thereto in desired positions to allow the assembly 10 including the component 12 to be secured to other components, parts, structures or assemblies as desired. By way of example, the fixings may be attached to the framework 16 by being welded thereto. Alternatively, openings may be drilled through the framework, prior to fitting the framework 16 to the component 12, to allow bolting or riveting of parts of the framework 16 to other components, parts or structures. The need to drill or cut into the component 12 or to adhesively bond fixings or the like thereto is thus avoided.

It will be appreciated that the use of the invention allows a ceramic composite component to be fixed or secured to other components, parts, structures or the like in a relatively simple and convenient form. The shape of the support 14 may be adapted to conform with the shape of the outer surface of components of a range of shapes and sizes. By way of example, it is envisaged that by appropriate CAD modelling, using data representative of the shape of the outer surface of a component (or part thereof), the elements for use in the formation of a framework of a suitable shape and size can readily be designed, and then cut and secured to one another to form the framework 16. Once the framework 16 has been assembled, it can be positioned around the component 12, and the spring clip arrangements 26 used to secure the ends of the loop parts 18, 20 to one another, to form interconnected closed loops located to both sides of the plane in which the component is of a maximum diameter or dimension, after which it will be appreciated that the component 12 is held captive by the support 14. The fixings attached to the support 14 can then be used to secure the assembly 10 including the component 12 in a desired position.

If desired, pads of a suitable material may be located between the support 14 and the component 12. By way of example, where the component 12 is subject to high temperatures, in use, the pads may be of a woven Kevlar material. However, other materials may be used without departing from the scope of the invention. The presence of the pads may permit a limited amount of relative motion to occur between the support 14 and the component 12, in use. It will be appreciated that the tensioning of the spring clip arrangement 26, in use, will tend to apply a compressive load to the pads.

Whilst one embodiment of the invention is described hereinbefore, it will be appreciated that a wide range of modifications and alterations may be made thereto without departing from the scope of the invention as defined by the appended claims. Whilst described in connection with a component in the form of a heat shield for a turbo charger, the invention is not restricted in this regard and may be applied to the support of other ceramic composite material components of a wide range of designs and for a wide range of functions.

Claims

CLAIMS:

1. An assembly comprising a ceramic composite material component and a support arrangement, the support arrangement comprising a support framework intimately fitted to an exterior of the component, the support framework being of a metallic material form.

2. An assembly according to Claim 1, wherein the framework is of an embossed material.

3. An assembly according to Claim 2, wherein the framework is of a 'crinkle' embossed material.

4. An assembly according to any of the preceding claims, wherein the framework comprises first and second loop parts of a diameter or dimension smaller than a maximum diameter or dimension of a part of the component, the first loop part being located to one side of the maximum diameter or dimension of the component, and the second loop part being located to the other side of the maximum diameter or dimension, the first and second loop parts being connected to one another by a series of connecting struts.

5. An assembly according to Claim 4, wherein each of the first and second loop parts incorporates a tension spring by which respective ends of the loop parts are secured to one another.

6. An assembly according to Claim 4 or Claim 5, wherein the loop parts and struts are welded to one another.

7. An assembly according to any of the preceding claims, wherein the metallic material comprises a stainless steel material.

8. An assembly according to any of Claims 1 to 6, wherein the metallic material is of titanium or Inconel form.

9. A support arrangement adapted for use in the assembly of any of the preceding claims.