Method for improving laminate quality during resin transfer molding

Patent metadata

Field	Value
Publication number	US-2016229130-A1
Application number	US-201514618191-A
Country	US
Kind code	A1
Filing date	Feb 10, 2015
Priority date	Feb 10, 2015
Publication date	Aug 11, 2016
Grant date	—

Abstract

A process for manufacturing a ceramic matrix composite component, said process comprising inserting at least one fibrous sheet into a resin transfer molding system. The process includes wetting the at least one fibrous sheet with a pre-ceramic polymer resin. The process includes applying a pressure to the at least one fibrous sheet and pre-ceramic polymer resin with an intensifier responsive to thermal expansion and curing the pre-ceramic polymer resin.

First claim

What is claimed is:

1 . A resin transfer molding system comprising:
a tool having an upper surface; a cover plate coupled with said tool proximate said upper surface; an inner cavity formed between said tool and said cover plate; an intensifier located in said inner cavity and thermally coupled to said tool; a thermal energy subsystem thermally coupled to said tool; and a vacuum pump fluidly coupled to said inner cavity.

2 . The system according to claim 1 , wherein said intensifier is proximate said upper surface.

3 . The system according to claim 1 , wherein said intensifier is configured to expand responsive to thermal energy.

4 . The system according to claim 1 , wherein said intensifier comprises a cured elastomer having a high coefficient of thermal expansion.

5 . The system according to claim 1 , wherein said intensifier comprises a silicone rubber material.

6 . The system according to claim 1 , further comprising a pump fluidly coupled to said inner cavity and configured to pump a resin into said inner cavity.

7 . The system according to claim 1 , further comprising:
a flexible bag insertable in said inner cavity between said cover plate and said intensifier; and a seal coupled between said cover plate and said tool and configured to fluidly seal said inner cavity.

8 . The system according to claim 1 , wherein said intensifier is configured to apply a pressure against at least one fibrous sheet wet up with pre-ceramic polymer resin insertable into said inner cavity adjacent said intensifier.

9 . A resin transfer molding system comprising:
a tool having an upper surface; a cover plate coupled with said tool proximate said upper surface; an inner cavity formed between said tool and said cover plate; an intensifier located in said inner cavity and thermally coupled to said tool; a thermal energy subsystem thermally coupled to said tool; and at least one fibrous sheet wet-up with a pre-ceramic polymer resin adjacent said intensifier; wherein said intensifier is configured to pressurize said at least one fibrous sheet wet-up with a pre-ceramic polymer resin responsive to thermal expansion of said intensifier.

10 . The system according to claim 9 , wherein said intensifier is configured to suppress void formation resultant from gases formed in said pre-ceramic polymer resin.

11 . The system according to claim 9 , wherein said intensifier is configured to apply a pressure of from about 50 pounds per square inch (psi) to as high as 800 psi.

12 . The system according to claim 9 , wherein said pre-ceramic polymer resin is selected from the group consisting of polycarbosilanes and polysilazanes.

13 . The system according to claim 9 , further comprising:
a thermal energy subsystem thermally coupled to said tool, said thermal energy subsystem configured to heat said intensifier at least one of a vacuum pump fluidly coupled to said inner cavity; and a pump fluidly coupled to said inner cavity; wherein said pump and said vacuum pump are configured to transport said resin into said inner cavity to wet-up said at least one fibrous sheet.

14 . A process for manufacturing a laminate ceramic composite component, said process comprising:
inserting at least one fibrous sheet into a resin transfer molding system; wetting said at least one fibrous sheet with a pre-ceramic polymer resin; applying a pressure to said at least one fibrous sheet and pre-ceramic polymer resin with an intensifier responsive to thermal expansion; and curing said pre-ceramic polymer resin.

15 . The process of claim 14 , further comprising:
suppressing void formation resultant from gases formed in said pre-ceramic polymer resin.

16 . The process of claim 14 , further comprising:
encapsulating said at least one fibrous sheet and pre-ceramic polymer resin between said intensifier and a cover plate; said cover plate being coupled to a tool.

17 . The process of claim 14 , wherein said intensifier comprises a cured elastomer having a high coefficient of thermal expansion.

18 . The process of claim 14 , further comprising:
heating said intensifier to induce a thermal expansion of said intensifier.

19 . The process of claim 14 , wherein said pre-ceramic polymer resin is selected from the group consisting of polycarbosilanes and polysilazanes.

20 . The process of claim 14 , further comprising:
Uniformly applying pressure to the at least one fibrous sheet and pre-ceramic polymer resin to ensure wet out and consolidation.

Assignees

• United Technologies Corp

Inventors

• Abbott Michael G
• Czaja Kathryn S
• Hertel Christopher J

Classifications

• C04B2235/48

  Organic compounds becoming part of a ceramic after heat treatment, e.g. carbonising phenol resins · CPC title

• B29C70/48

  and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM] {, e.g. by vacuum} · CPC title

• B29K2883/00

  Use of polymers having silicon, with or without sulfur, nitrogen, oxygen, or carbon only, in the main chain, as mould material · CPC title

• F16D69/023

  Composite materials containing carbon and carbon fibres or fibres made of carbonizable material · CPC title

• B29K2105/0809

  Fabrics · CPC title