JP4794607B2 - 複合セラミック構造、およびセラミック複合構造を製造する方法 - Google Patents
複合セラミック構造、およびセラミック複合構造を製造する方法 Download PDFInfo
- Publication number
- JP4794607B2 JP4794607B2 JP2008186081A JP2008186081A JP4794607B2 JP 4794607 B2 JP4794607 B2 JP 4794607B2 JP 2008186081 A JP2008186081 A JP 2008186081A JP 2008186081 A JP2008186081 A JP 2008186081A JP 4794607 B2 JP4794607 B2 JP 4794607B2
- Authority
- JP
- Japan
- Prior art keywords
- ceramic
- pin
- composite
- core
- pins
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Active
Links
- 239000000919 ceramic Substances 0.000 title claims description 159
- 239000002131 composite material Substances 0.000 title claims description 69
- 238000004519 manufacturing process Methods 0.000 title claims description 48
- 238000000034 method Methods 0.000 claims description 56
- 239000000835 fiber Substances 0.000 claims description 52
- 239000011230 binding agent Substances 0.000 claims description 26
- 239000000463 material Substances 0.000 claims description 19
- 238000005452 bending Methods 0.000 claims description 9
- 239000006260 foam Substances 0.000 claims description 8
- 238000005304 joining Methods 0.000 claims description 7
- 239000011253 protective coating Substances 0.000 claims description 7
- 238000005530 etching Methods 0.000 claims description 6
- 238000002679 ablation Methods 0.000 claims description 5
- 238000005520 cutting process Methods 0.000 claims description 3
- 239000004616 structural foam Substances 0.000 claims description 3
- 239000011159 matrix material Substances 0.000 description 34
- 239000011153 ceramic matrix composite Substances 0.000 description 31
- 239000010410 layer Substances 0.000 description 25
- 230000008569 process Effects 0.000 description 21
- 238000000227 grinding Methods 0.000 description 6
- 229910010293 ceramic material Inorganic materials 0.000 description 4
- 239000011248 coating agent Substances 0.000 description 4
- 238000000576 coating method Methods 0.000 description 4
- 239000002002 slurry Substances 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- 239000004593 Epoxy Substances 0.000 description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- 239000000853 adhesive Substances 0.000 description 2
- 230000001070 adhesive effect Effects 0.000 description 2
- 239000012790 adhesive layer Substances 0.000 description 2
- 230000007797 corrosion Effects 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- 238000013461 design Methods 0.000 description 2
- 238000003780 insertion Methods 0.000 description 2
- 230000037431 insertion Effects 0.000 description 2
- 238000012423 maintenance Methods 0.000 description 2
- 230000000149 penetrating effect Effects 0.000 description 2
- 229910052582 BN Inorganic materials 0.000 description 1
- 229910052581 Si3N4 Inorganic materials 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- CFOAUMXQOCBWNJ-UHFFFAOYSA-N [B].[Si] Chemical compound [B].[Si] CFOAUMXQOCBWNJ-UHFFFAOYSA-N 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 229910000323 aluminium silicate Inorganic materials 0.000 description 1
- 239000012876 carrier material Substances 0.000 description 1
- 238000003486 chemical etching Methods 0.000 description 1
- 238000001311 chemical methods and process Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 230000008020 evaporation Effects 0.000 description 1
- 238000001704 evaporation Methods 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- 238000010304 firing Methods 0.000 description 1
- 239000006261 foam material Substances 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 239000012212 insulator Substances 0.000 description 1
- 230000010354 integration Effects 0.000 description 1
- 239000004620 low density foam Substances 0.000 description 1
- 238000010297 mechanical methods and process Methods 0.000 description 1
- 230000005226 mechanical processes and functions Effects 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008520 organization Effects 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 230000037452 priming Effects 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- 230000008439 repair process Effects 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
- 230000001052 transient effect Effects 0.000 description 1
- 238000009834 vaporization Methods 0.000 description 1
- 230000008016 vaporization Effects 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/08—Interconnection of layers by mechanical means
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
- B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
- B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
- B32B9/005—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising one layer of ceramic material, e.g. porcelain, ceramic tile
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
- B32B9/04—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B9/047—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material made of fibres or filaments
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/628—Coating the powders or the macroscopic reinforcing agents
- C04B35/62844—Coating fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2250/00—Layers arrangement
- B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B2260/02—Composition of the impregnated, bonded or embedded layer
- B32B2260/021—Fibrous or filamentary layer
- B32B2260/023—Two or more layers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/10—Inorganic fibres
- B32B2262/105—Ceramic fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2266/00—Composition of foam
- B32B2266/08—Closed cell foam
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/30—Properties of the layers or laminate having particular thermal properties
- B32B2307/306—Resistant to heat
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2605/00—Vehicles
- B32B2605/08—Cars
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2605/00—Vehicles
- B32B2605/18—Aircraft
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49826—Assembling or joining
- Y10T29/49904—Assembling a subassembly, then assembling with a second subassembly
Landscapes
- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Ceramic Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Inorganic Chemistry (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Organic Chemistry (AREA)
- Laminated Bodies (AREA)
Description
セラミックマトリックス複合(ceramic matrix composite:CMC)構造は、それらの比較的高い動作温度に耐える能力のために、航空宇宙用途および他の用途において使用され得る。たとえば、CMC構造は、航空機用途において高温の排気ガスに晒される部品を作製するために使用されてもよい。ある種類のCMC構造は、2つのCMC表面板がコアに接合されているサンドイッチ構成を採用している。あるサンドイッチ構成では、コアは、コアの厚みを通って延在して表面板を貫通するCMCピンのトラス状の配列によって補強されてもよい。これらのピンは、表面板間で圧縮荷重、引張荷重および/またはせん断荷重を伝える荷重経路を提供する。しかしながら、この先行技術のピン/トラス構成の荷重担持能力は、特に表面板が比較的薄い場合、ピンの端と表面板の層との間の接合強度が制限されるために、制限されている。
CMC構造は、セラミックトラス補強コアを有するサンドイッチ構成を含む。トラスを形成するCMCピンの外端を曲げることにより、コアと表面板との間の優れた接合が得られる。CMCピンの端を曲げることにより、ピンと表面板との間により大きな接合区域が提供され、それにより、コアの荷重伝達能力が向上する。CMCピンの端は、セラミックファイバを束ねるマトリックス材料をピンの端から除去することにより、曲げられてもよい。マトリックス材料が除去されると、残りのセラミック繊維は比較的しなやかになり、それらは、表面板の平坦面に平行に延在してそれと接合され得るように曲げられるようになる。
るセラミックトラスを含むコアを形成するステップと、
(B) セラミック繊維を露出させるためにピンの端から結合剤を除去するステップと、
(C) ピンの端を曲げるステップと、
(D) ピンの端に表面板を接合するステップとを含む、セラミック複合構造を製造する方法。
セラミック複合構造を製造する方法を用いた、航空機のサブアセンブリの作製。
(A) 複数の複合セラミックピンを用いてセラミックトラスを形成するステップを含み、複合セラミックピンは、マトリックス内に保持されたセラミック繊維を含み、前記方法はさらに、
(B) セラミック繊維を露出させるためにピンの端からマトリックスを除去するステップを含む、セラミック複合構造に使用されるセラミックトラスコアを製造する方法。
ピンストックを担体材料に挿入するステップと、
ピンの端が担体を超えて延在するような長さにピンストックを切断するステップとを含む、セラミック複合構造に使用されるセラミックトラスコアを製造する方法。
(ii)セラミック複合ピンの端が担体から突出するように担体内の配列の一部を包囲し、
(iii)セラミック繊維の一部を露出させるために、ピンの突出端からマトリックスを除去し、
(iv)セラミック繊維の露出した一部を曲げることにより、
コアを作製するステップと、
(B) セラミック繊維の露出して曲げられた端に表面板を接合することにより、表面板をコアに接合するステップとを含む、セラミック複合構造を製造する方法。
セラミック複合構造を製造する方法を用いた、航空機のサブアセンブリの作製。
まず図1を参照すると、典型的な先行技術のCMCサンドイッチ構成は、セラミックピン18の配列を含むコアに接合された1対の平行なCMC表面板14、16を含む。ピン18は「X」型に配置されており、構造発泡材(図示せず)を含み得るコアを補強するよう機能する。ピン18の各々は真っ直ぐで、表面板14、16を通って延在して表面板14、16に接合される外端を有する。ピン18と表面板14、16との間の接合区域は、
表面板14、16へのピン18の端の貫通部の深さに制限されている。
、アルミノシリケート アルミノボロシリケート、窒化シリコン、ホウ化シリコン、窒化ホウ素シリコン、および同様の材料を含み得るがこれらに限定されない。トラス構造25は、サンドイッチ構成20を補強する荷重経路を規定しており、所望すれば、自己を支持しかつ荷重を担持するCMC構造の作製を可能にする。CMCサンドイッチ20は、サンドイッチ20に使用される構成要素がすべてセラミックベースなので、高温用途に特に良好に適合する。
各々における末端部28bは、表面板24、26の平面に略平行に延在するよう曲げられる。末端部28bの長さは特定の用途に依存し、一実施例では、ピン28の直径の4〜5倍に略等しい長さが、満足のいく結果をもたらした。
の外端が担体30から突出して露出したままとなるように行なわれる。
6の例は、推進システム102、電気システム104、油圧システム106、および環境システム108のうちの1つ以上を含む。任意の数の他のシステムが含まれていてもよい。航空宇宙産業の例が示されているが、この発明の原理は、自動車業界など他の業界に適用されてもよい。
また、本発明は以下に記載する態様を含む。
(態様1)
(A) 硬質の結合剤内に保持されたセラミック繊維から形成された複数のピンを有するセラミックトラスを含むコアを形成するステップと、
(B) セラミック繊維を露出させるためにピンの端から結合剤を除去するステップと、
(C) ピンの端を曲げるステップと、
(D) ピンの端に表面板を接合するステップとを含む、セラミック複合構造を製造する方法。
(態様2)
ステップ(A)は、
ある長さのピンストックを担体に挿入するステップと、
ピンの端が露出されるように前記長さのピンストックを切断するステップとを含む、態様1に記載の方法。
(態様3)
ピンストックは発泡材の層に挿入される、態様2に記載の方法。
(態様4)
(E) ステップ(B)での結合剤の除去中、コアの一部に保護コーティングを施すことによってコアの一部を保護するステップをさらに含む、態様1に記載の方法。
(態様5)
ステップ(B)は、ピンの端をエッチングすることによって行なわれる、態様1に記載の方法。
(態様6)
ステップ(B)は、ピンの端を粉砕することによって行なわれる、態様1に記載の方法。
(態様7)
ステップ(B)は、アブレーションによって行なわれる、態様1に記載の方法。
(態様8)
ステップ(C)は、
表面板を露出したセラミック繊維と接触させ、
前記表面板を用いて、露出したセラミック繊維を曲げることによって行なわれる、態様1に記載の方法。
(態様9)
ステップ(C)は、セラミックプリプレグの層の間で、露出したセラミック繊維を接合するステップを含む、態様1に記載の方法。
(態様10)
(F) 複合構造を含む航空機サブアセンブリを特定し、設計するステップをさらに含む、態様1に記載の方法。
(態様11)
(G) 複合構造の製造に使用される材料を調達するステップをさらに含む、態様1に記載の方法。
(態様12)
1対の略平行な複合セラミック表面板と、
表面板間に配置され、表面板に接合されたコアとを含む、複合セラミック構造であって、コアはセラミックトラスを含み、
トラスは複数の複合セラミックピンを含み、ピンの各々は、表面板に対して略直角に延在する中間部と、表面板に略平行に延在し、表面板に接合された末端部とを含む、複合セラミック構造。
(態様13)
表面板のうちの少なくとも1つは多数の層を含み、ピンの末端部は前記層の間に挟まれている、態様12に記載の複合セラミック構造。
(態様14)
ピンのうちの少なくとも一部は延在し、ピンは、表面板に垂直に延在する軸に対して約30度の角度を形成する、態様12に記載の複合セラミック構造。
(態様15)
ピンの末端部は、表面板の内側の対向面に接合される、態様12に記載の複合セラミック構造。
(態様16)
コアは、セラミックトラスを包囲する構造発泡材をさらに含む、態様12に記載の複合セラミック構造。
Claims (15)
- (A) 硬質の結合剤内に保持されたセラミック繊維から形成された複数のピンを有するセラミックトラスを含むコアを形成するステップと、
(B) セラミック繊維を露出させるためにピンの端から結合剤を除去するステップと、
(C) ピンの端を曲げるステップと、
(D) ピンの端に表面板を接合するステップとを含む、セラミック複合構造を製造する方法。 - ステップ(A)は、
ある長さのピンストックを担体に挿入するステップと、
ピンの端が露出されるように前記長さのピンストックを切断するステップとを含む、請求項1に記載の方法。 - ピンストックは発泡材の層に挿入される、請求項2に記載の方法。
- (E) ステップ(B)での結合剤の除去中、コアの一部に保護コーティングを施すことによってコアの一部を保護するステップをさらに含む、請求項1に記載の方法。
- ステップ(B)は、ピンの端をエッチングすることによって行なわれる、請求項1に記載の方法。
- ステップ(B)は、ピンの端を粉砕することによって行なわれる、請求項1に記載の方法。
- ステップ(B)は、アブレーションによって行なわれる、請求項1に記載の方法。
- ステップ(C)は、
表面板を露出したセラミック繊維と接触させ、
前記表面板を用いて、露出したセラミック繊維を曲げることによって行なわれる、請求項1に記載の方法。 - ステップ(C)は、セラミックプリプレグの層の間で、露出したセラミック繊維を接合するステップを含む、請求項1に記載の方法。
- (F) 複合構造を含む航空機サブアセンブリを特定し、設計するステップをさらに含む、請求項1に記載の方法。
- (G) 複合構造の製造に使用される材料を調達するステップをさらに含む、請求項1に記載の方法。
- 1対の略平行な複合セラミック表面板と、
表面板間に配置され、表面板に接合されたコアとを含む、複合セラミック構造であって、コアはセラミックトラスを含み、
トラスは複数の複合セラミックピンを含み、ピンの各々は、表面板に対して垂直に延在する軸に約30°の角度をなして、表面板へ延在する中間部と、表面板に略平行に延在し、表面板に接合された末端部とを含み、前記複合セラミックピンの各々は、硬質の結合剤と該結合剤中に保持されたセラミック繊維とを有し、ピンの前記末端部において該結合剤が除去されている、複合セラミック構造。 - 表面板のうちの少なくとも1つは多数の層を含み、ピンの末端部は前記層の間に挟まれている、請求項12に記載の複合セラミック構造。
- ピンの末端部は、表面板の内側の対向面に接合される、請求項12に記載の複合セラミック構造。
- コアは、セラミックトラスを包囲する構造発泡材をさらに含む、請求項12に記載の複合セラミック構造。
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/779,439 US9782951B2 (en) | 2007-07-18 | 2007-07-18 | Composite structure having ceramic truss core and method for making the same |
US11/779,439 | 2007-07-18 |
Publications (2)
Publication Number | Publication Date |
---|---|
JP2009023348A JP2009023348A (ja) | 2009-02-05 |
JP4794607B2 true JP4794607B2 (ja) | 2011-10-19 |
Family
ID=39863092
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
JP2008186081A Active JP4794607B2 (ja) | 2007-07-18 | 2008-07-17 | 複合セラミック構造、およびセラミック複合構造を製造する方法 |
Country Status (8)
Country | Link |
---|---|
US (1) | US9782951B2 (ja) |
EP (1) | EP2017073B1 (ja) |
JP (1) | JP4794607B2 (ja) |
CN (2) | CN103819198A (ja) |
AU (1) | AU2008202942B2 (ja) |
CA (1) | CA2635305C (ja) |
ES (1) | ES2430208T3 (ja) |
PT (1) | PT2017073E (ja) |
Families Citing this family (13)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US9586699B1 (en) | 1999-08-16 | 2017-03-07 | Smart Drilling And Completion, Inc. | Methods and apparatus for monitoring and fixing holes in composite aircraft |
US9625361B1 (en) | 2001-08-19 | 2017-04-18 | Smart Drilling And Completion, Inc. | Methods and apparatus to prevent failures of fiber-reinforced composite materials under compressive stresses caused by fluids and gases invading microfractures in the materials |
US20090004425A1 (en) * | 2007-06-28 | 2009-01-01 | The Boeing Company | Ceramic Matrix Composite Structure having Fluted Core and Method for Making the Same |
US9782951B2 (en) | 2007-07-18 | 2017-10-10 | The Boeing Company | Composite structure having ceramic truss core and method for making the same |
US8512853B2 (en) | 2007-07-31 | 2013-08-20 | The Boeing Company | Composite structure having reinforced core |
US8431214B2 (en) * | 2007-07-31 | 2013-04-30 | The Boeing Company | Composite structure having reinforced core and method of making same |
US8626478B1 (en) | 2010-07-16 | 2014-01-07 | The Boeing Company | Cross flow parameter calculation for aerodynamic analysis |
US9545774B1 (en) * | 2011-11-07 | 2017-01-17 | The Boeing Company | Reworking ceramic sandwich structures |
US8894919B1 (en) | 2012-07-18 | 2014-11-25 | The Boeing Company | Method for incorporation of insulators and bulk absorbers in high temperature sandwich structures after fabrication |
PL3250375T3 (pl) * | 2015-01-28 | 2022-11-21 | Composite Research S.R.L. | Panel z materiału kompozytowego, mający strukturę warstwową |
US20160236989A1 (en) * | 2015-02-17 | 2016-08-18 | United Technologies Corporation | Toughened bond layer and method of production |
US10894746B2 (en) * | 2016-10-19 | 2021-01-19 | Rolls-Royce Corporation | Ceramic matrix composite reinforced material |
US10794205B2 (en) | 2017-02-27 | 2020-10-06 | Rolls-Royce North American Technologies Inc. | Ceramic seal component for gas turbine engine and process of making the same |
Family Cites Families (67)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3579411A (en) * | 1967-09-27 | 1971-05-18 | William L Mackie | Filament reinforced structure and method of making |
US4103470A (en) | 1976-10-14 | 1978-08-01 | Cook Charles E | Stressed skin structural diaphragm |
US4113549A (en) * | 1977-04-06 | 1978-09-12 | Chem-Tronics, Inc. | Chemical milling process |
US4151031A (en) * | 1977-07-05 | 1979-04-24 | General Dynamics Corporation | Apparatus for continuously forming composite shapes |
US4588474A (en) * | 1981-02-03 | 1986-05-13 | Chem-Tronics, Incorporated | Chemical milling processes and etchants therefor |
US4361613A (en) * | 1981-09-21 | 1982-11-30 | The Quaker Oats Company | Composite construction materials with improved fire resistance |
US4556591A (en) * | 1981-09-25 | 1985-12-03 | The Boeing Company | Conductive bonded/bolted joint seals for composite aircraft |
US4556592A (en) * | 1981-09-25 | 1985-12-03 | The Boeing Company | Conductive joint seals for composite aircraft |
US4614013A (en) | 1984-02-21 | 1986-09-30 | David Stevenson | Method of forming a reinforced structural building panel |
US4709714A (en) | 1984-08-06 | 1987-12-01 | Hitachi Zosen Corporation | Apparatus for exposing fibrous reinforcements of fiber reinforced resin body |
JPS6142544A (ja) * | 1984-08-06 | 1986-03-01 | Hitachi Zosen Corp | 繊維強化樹脂体の樹脂融解方法 |
US4664731A (en) * | 1985-01-07 | 1987-05-12 | The United States Of America As Represented By The Secretary Of The Navy | Pultrusion of glass and glass-ceramic matrix composites |
US4786343A (en) * | 1985-05-10 | 1988-11-22 | The Boeing Company | Method of making delamination resistant composites |
US4822660A (en) | 1987-06-02 | 1989-04-18 | Corning Glass Works | Lightweight ceramic structures and method |
US4808461A (en) * | 1987-12-14 | 1989-02-28 | Foster-Miller, Inc. | Composite structure reinforcement |
US5102723A (en) | 1989-11-13 | 1992-04-07 | Pepin John N | Structural sandwich panel with energy-absorbing material pierced by rigid rods |
JP2914386B2 (ja) * | 1989-11-15 | 1999-06-28 | クロマロイ・ガス・タービン・コーポレーション | 繊維強化セラミック複合材の被覆方法及びその被覆複合材 |
DE4030529A1 (de) | 1990-09-27 | 1992-04-02 | Dornier Gmbh | Verfahren zur herstellung von sandwichstrukturen aus faserverstaerkter keramik |
US5177039A (en) * | 1990-12-06 | 1993-01-05 | Corning Incorporated | Method for making ceramic matrix composites |
GB2253185A (en) * | 1991-03-01 | 1992-09-02 | Secr Defence | Reinforced alloy laminates |
US5225015A (en) * | 1991-04-15 | 1993-07-06 | Corning Incorporated | Method for making stiffened ceramic matrix composite panel |
AU671749B2 (en) * | 1993-04-30 | 1996-09-05 | Foster-Miller Inc. | A reinforced joint for composite structures and method of joining composite parts |
US5474635A (en) * | 1994-03-07 | 1995-12-12 | United Technologies Corporation | Joining non-coplanar panels and structures of fiber reinforced composites |
WO1997006948A1 (en) * | 1995-08-21 | 1997-02-27 | Foster-Miller, Inc. | System for inserting elements in composite structure |
WO1996018494A1 (en) * | 1994-12-13 | 1996-06-20 | Dow-United Technologies Composite Products, Inc. | Shaped unidirectional fiber filler |
US6027798A (en) | 1995-11-01 | 2000-02-22 | The Boeing Company | Pin-reinforced sandwich structure |
US5789061A (en) * | 1996-02-13 | 1998-08-04 | Foster-Miller, Inc. | Stiffener reinforced assembly and method of manufacturing same |
US5876652A (en) | 1996-04-05 | 1999-03-02 | The Boeing Company | Method for improving pulloff strength in pin-reinforced sandwich structure |
EP0954660B1 (de) * | 1997-01-23 | 2001-06-27 | Sika AG, vorm. Kaspar Winkler & Co. | Flachband-lamelle zur verstärkung von bauteilen sowie verfahren zu deren herstellung |
US6291049B1 (en) * | 1998-10-20 | 2001-09-18 | Aztex, Inc. | Sandwich structure and method of making same |
JP2000351189A (ja) * | 1999-06-11 | 2000-12-19 | Toyota Motor Corp | シート状材料のプレス接合方法 |
AU2459101A (en) * | 1999-12-28 | 2001-07-09 | Webcore Technologies, Inc. | Fiber reinforced composite cores and panels |
TR200501818T2 (tr) | 2000-04-24 | 2006-12-21 | Hunterdouglasindustriesb.V. | Sıkıştınlabilir yapısal panel |
US20020007607A1 (en) | 2000-07-12 | 2002-01-24 | Christopher Matlack | Laminated protective wrap |
US7264991B1 (en) * | 2000-10-13 | 2007-09-04 | Bridge Semiconductor Corporation | Method of connecting a conductive trace to a semiconductor chip using conductive adhesive |
US7056576B2 (en) * | 2001-04-06 | 2006-06-06 | Ebert Composites, Inc. | 3D fiber elements with high moment of inertia characteristics in composite sandwich laminates |
US6645333B2 (en) * | 2001-04-06 | 2003-11-11 | Ebert Composites Corporation | Method of inserting z-axis reinforcing fibers into a composite laminate |
US7785693B2 (en) * | 2001-04-06 | 2010-08-31 | Ebert Composites Corporation | Composite laminate structure |
US7105071B2 (en) * | 2001-04-06 | 2006-09-12 | Ebert Composites Corporation | Method of inserting z-axis reinforcing fibers into a composite laminate |
US7731046B2 (en) * | 2001-04-06 | 2010-06-08 | Ebert Composites Corporation | Composite sandwich panel and method of making same |
US20050025948A1 (en) | 2001-04-06 | 2005-02-03 | Johnson David W. | Composite laminate reinforced with curvilinear 3-D fiber and method of making the same |
US6676785B2 (en) | 2001-04-06 | 2004-01-13 | Ebert Composites Corporation | Method of clinching the top and bottom ends of Z-axis fibers into the respective top and bottom surfaces of a composite laminate |
US6746755B2 (en) | 2001-09-24 | 2004-06-08 | Siemens Westinghouse Power Corporation | Ceramic matrix composite structure having integral cooling passages and method of manufacture |
DE10159067A1 (de) * | 2001-12-01 | 2003-06-26 | Daimler Chrysler Ag | Faserverbund-Crashstruktur |
US6716782B2 (en) | 2002-08-16 | 2004-04-06 | The Boeing Company | Rigid insulation and method of producing same |
AU2003270086A1 (en) * | 2002-09-03 | 2004-03-29 | University Of Virginia Patent Foundation | Method for manufacture of truss core sandwich structures and related structures thereof |
FR2852004B1 (fr) * | 2003-03-04 | 2005-05-27 | Snecma Propulsion Solide | Realisation d'une preforme par renforcement d'une structure fibreuse et/ou par liaison entre elles de structures fibreuses et application a la realisation de pieces en materiau composite |
US20070020960A1 (en) * | 2003-04-11 | 2007-01-25 | Williams John D | Contact grid array system |
US6969546B2 (en) | 2003-10-20 | 2005-11-29 | The Boeing Company | Thermal insulation system employing oxide ceramic matrix composites |
US7312274B2 (en) | 2003-11-24 | 2007-12-25 | General Electric Company | Composition and method for use with ceramic matrix composite T-sections |
EP1596024A1 (en) * | 2004-05-11 | 2005-11-16 | Groep Stevens International, Naamloze Vennootschap | Reinforced sandwich panel |
US8601694B2 (en) * | 2008-06-13 | 2013-12-10 | The Boeing Company | Method for forming and installing stringers |
JP2006347134A (ja) * | 2005-06-20 | 2006-12-28 | Toyota Motor Corp | 繊維強化樹脂積層体及び繊維強化樹脂積層体の製造方法 |
US8709584B2 (en) | 2006-01-31 | 2014-04-29 | Sikorsky Aircraft Corporation | Composite aircraft floor system |
GB2440133A (en) * | 2006-07-18 | 2008-01-23 | Gkn Aerospace Transparency Sys | A de-icing heated leading edge component of an aircraft |
US8038894B2 (en) * | 2006-11-29 | 2011-10-18 | General Electric Company | Method of selectively stripping an engine-run ceramic coating |
DE102006056568A1 (de) | 2006-11-30 | 2008-06-05 | Airbus Deutschland Gmbh | Kernstruktur und Verfahren zur Herstellung einer Kernstruktur |
US7891096B2 (en) * | 2007-01-23 | 2011-02-22 | Airbus Deutschland Gmbh | Method for reinforcing a foam material as well as a sandwich component |
US8889216B2 (en) * | 2007-05-31 | 2014-11-18 | Nthdegree Technologies Worldwide Inc | Method of manufacturing addressable and static electronic displays |
US8097106B2 (en) | 2007-06-28 | 2012-01-17 | The Boeing Company | Method for fabricating composite structures having reinforced edge bonded joints |
US9782951B2 (en) | 2007-07-18 | 2017-10-10 | The Boeing Company | Composite structure having ceramic truss core and method for making the same |
US8512853B2 (en) | 2007-07-31 | 2013-08-20 | The Boeing Company | Composite structure having reinforced core |
US8431214B2 (en) * | 2007-07-31 | 2013-04-30 | The Boeing Company | Composite structure having reinforced core and method of making same |
EP2052846B1 (en) * | 2007-10-25 | 2013-12-11 | Saab Ab | Method of forming a T-shaped composite structure comprising a radius filler and radius filler |
US8127450B2 (en) * | 2008-01-31 | 2012-03-06 | Airbus Operations Gmbh | Method for producing a sandwich construction, in particular a sandwich construction for the aeronautical and aerospace fields |
US8349105B2 (en) * | 2008-04-17 | 2013-01-08 | The Boeing Company | Curved composite frames and method of making the same |
US9370921B2 (en) * | 2012-11-01 | 2016-06-21 | The Boeing Company | Composite radius fillers and methods of forming the same |
-
2007
- 2007-07-18 US US11/779,439 patent/US9782951B2/en active Active
-
2008
- 2008-06-19 CA CA2635305A patent/CA2635305C/en active Active
- 2008-07-03 AU AU2008202942A patent/AU2008202942B2/en active Active
- 2008-07-10 EP EP08252351.5A patent/EP2017073B1/en active Active
- 2008-07-10 PT PT82523515T patent/PT2017073E/pt unknown
- 2008-07-10 ES ES08252351T patent/ES2430208T3/es active Active
- 2008-07-17 JP JP2008186081A patent/JP4794607B2/ja active Active
- 2008-07-18 CN CN201410057542.2A patent/CN103819198A/zh active Pending
- 2008-07-18 CN CNA200810137725XA patent/CN101348380A/zh active Pending
Also Published As
Publication number | Publication date |
---|---|
EP2017073B1 (en) | 2013-09-25 |
AU2008202942B2 (en) | 2012-04-19 |
ES2430208T3 (es) | 2013-11-19 |
AU2008202942A1 (en) | 2009-02-05 |
CA2635305A1 (en) | 2009-01-18 |
JP2009023348A (ja) | 2009-02-05 |
CN103819198A (zh) | 2014-05-28 |
US20090019685A1 (en) | 2009-01-22 |
CN101348380A (zh) | 2009-01-21 |
US9782951B2 (en) | 2017-10-10 |
PT2017073E (pt) | 2013-11-19 |
EP2017073A3 (en) | 2012-01-04 |
CA2635305C (en) | 2011-03-15 |
EP2017073A2 (en) | 2009-01-21 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
JP4794607B2 (ja) | 複合セラミック構造、およびセラミック複合構造を製造する方法 | |
EP2008807B1 (en) | Ceramic matrix composite structure having fluted core and method of making the same | |
US4849276A (en) | Thermal insulation structure | |
US8097106B2 (en) | Method for fabricating composite structures having reinforced edge bonded joints | |
JP5670019B2 (ja) | 可撓性のセラミックマトリックス複合構造材料及びその形成方法 | |
US5000998A (en) | Method for making thermal insulation | |
JP5638397B2 (ja) | 複合部品を製造するための熱効率の高いツール | |
KR20170021194A (ko) | 어쿠스틱 샌드위치 패널 및 방법 | |
US7485354B2 (en) | Thermal protection system for a vehicle | |
JP2009143540A (ja) | 補強されたコアを有している複合構造及び複合構造を作る方法 | |
US6607851B2 (en) | Multi-layer ceramic fiber insulation tile | |
US8262840B2 (en) | Composite material structure with interlayer electrical conductance | |
US20070224407A1 (en) | Low-density ablative heat shield fabrication | |
Bent et al. | Recent advances in active fiber composites for structural control | |
US9545774B1 (en) | Reworking ceramic sandwich structures | |
JP2003326622A (ja) | 高熱伝導ハニカムサンドイッチパネルおよびこれを備えた人工衛星用機器搭載パネル | |
US5851645A (en) | Composite structure having an externally accessible electrical device embedded therein and a related fabrication method | |
JP3787989B2 (ja) | ハニカムサンドイッチパネル |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
RD03 | Notification of appointment of power of attorney |
Free format text: JAPANESE INTERMEDIATE CODE: A7423 Effective date: 20091111 |
|
A521 | Request for written amendment filed |
Free format text: JAPANESE INTERMEDIATE CODE: A821 Effective date: 20100303 |
|
RD04 | Notification of resignation of power of attorney |
Free format text: JAPANESE INTERMEDIATE CODE: A7424 Effective date: 20100303 |
|
A977 | Report on retrieval |
Free format text: JAPANESE INTERMEDIATE CODE: A971007 Effective date: 20101208 |
|
A131 | Notification of reasons for refusal |
Free format text: JAPANESE INTERMEDIATE CODE: A131 Effective date: 20110118 |
|
A601 | Written request for extension of time |
Free format text: JAPANESE INTERMEDIATE CODE: A601 Effective date: 20110415 |
|
A602 | Written permission of extension of time |
Free format text: JAPANESE INTERMEDIATE CODE: A602 Effective date: 20110420 |
|
A521 | Request for written amendment filed |
Free format text: JAPANESE INTERMEDIATE CODE: A523 Effective date: 20110516 |
|
TRDD | Decision of grant or rejection written | ||
A01 | Written decision to grant a patent or to grant a registration (utility model) |
Free format text: JAPANESE INTERMEDIATE CODE: A01 Effective date: 20110628 |
|
A01 | Written decision to grant a patent or to grant a registration (utility model) |
Free format text: JAPANESE INTERMEDIATE CODE: A01 |
|
A61 | First payment of annual fees (during grant procedure) |
Free format text: JAPANESE INTERMEDIATE CODE: A61 Effective date: 20110726 |
|
R150 | Certificate of patent or registration of utility model |
Free format text: JAPANESE INTERMEDIATE CODE: R150 Ref document number: 4794607 Country of ref document: JP Free format text: JAPANESE INTERMEDIATE CODE: R150 |
|
FPAY | Renewal fee payment (event date is renewal date of database) |
Free format text: PAYMENT UNTIL: 20140805 Year of fee payment: 3 |
|
R250 | Receipt of annual fees |
Free format text: JAPANESE INTERMEDIATE CODE: R250 |
|
R250 | Receipt of annual fees |
Free format text: JAPANESE INTERMEDIATE CODE: R250 |
|
R250 | Receipt of annual fees |
Free format text: JAPANESE INTERMEDIATE CODE: R250 |
|
R250 | Receipt of annual fees |
Free format text: JAPANESE INTERMEDIATE CODE: R250 |
|
R250 | Receipt of annual fees |
Free format text: JAPANESE INTERMEDIATE CODE: R250 |
|
R250 | Receipt of annual fees |
Free format text: JAPANESE INTERMEDIATE CODE: R250 |
|
R250 | Receipt of annual fees |
Free format text: JAPANESE INTERMEDIATE CODE: R250 |
|
R250 | Receipt of annual fees |
Free format text: JAPANESE INTERMEDIATE CODE: R250 |
|
R250 | Receipt of annual fees |
Free format text: JAPANESE INTERMEDIATE CODE: R250 |
|
R250 | Receipt of annual fees |
Free format text: JAPANESE INTERMEDIATE CODE: R250 |
|
R250 | Receipt of annual fees |
Free format text: JAPANESE INTERMEDIATE CODE: R250 |