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91. 发明申请

US20100119777A1 Ceramic matrix composite surfaces with open features for improved bonding to coatings 审中-公开
标题翻译：具有开放特征的陶瓷基体复合材料表面，用于改善与涂层的结合
公开(公告)号：US20100119777A1
公开(公告)日：2010-05-13
申请号：US11600709
申请日：2006-11-16
申请人： Gary B. Merrill , Jay A. Morrison , Jay E. Lane , Steven James Vance
发明人： Gary B. Merrill , Jay A. Morrison , Jay E. Lane , Steven James Vance
IPC分类号： B32B3/30 , B05D3/12
CPC分类号： C04B41/5027 , B32B5/12 , B32B5/26 , B32B5/30 , B32B2260/025 , B32B2264/107 , B32B2307/304 , C04B41/009 , C04B41/87 , D03D15/0016 , D03D15/02 , D03D25/005 , D04C1/06 , D10B2505/02 , F05C2253/02 , F05C2253/04 , F05C2253/12 , Y10T428/24479 , C04B20/004 , C04B35/80
摘要： A method to form an improved hybrid ceramic matrix composite structure comprises providing a ceramic matrix composite (CMC) with open features at a surface and applying a thermal barrier coating to the surface. The thermal barrier coating is preferably a friable graded insulation coating (FGI) having hollow ceramic spheres. For acceptance of a FGI coating the open features have a center-to-center separation distance in one or more directions that is between about 100 and about 1,000 percent of the diameter of the hollow ceramic spheres in the FGI and a depth that is between about 20 percent and about 200 percent of the diameter of the hollow ceramic spheres in the FGI. The open feature can result from the winding of tows about a mandrel; the lay-up of fabric including a surface fabric having an open weave; or the use of a 3-D weave, or a 3-D braid.
摘要翻译：形成改进的混合陶瓷基质复合结构的方法包括提供在表面上具有开放特征的陶瓷基质复合材料（CMC），并向表面施加热障涂层。隔热涂层优选是具有中空陶瓷球的易碎梯度绝缘涂层（FGI）。为了接受FGI涂层，开口特征在一个或多个方向上具有中心到中心的间隔距离，其在FGI中的中空陶瓷球的直径的大约100％到大约1000％之间，并且在大约在FGI中的中空陶瓷球的直径的20％和约200％。打开的特征可以由围绕心轴缠绕的丝束产生; 包括具有开放编织物的表面织物的织物铺设; 或使用3-D编织物或3-D编织物。

92. 发明申请

US20100021643A1 Method of Forming a Turbine Engine Component Having a Vapor Resistant Layer 审中-公开
标题翻译：形成具有耐蒸汽层的涡轮发动机部件的方法
公开(公告)号：US20100021643A1
公开(公告)日：2010-01-28
申请号：US12177567
申请日：2008-07-22
申请人： Jay E. Lane , Gary B. Merrill
发明人： Jay E. Lane , Gary B. Merrill
IPC分类号： B05D3/08
CPC分类号： F01D5/282 , F01D5/284 , F05D2230/21 , F05D2300/603 , F05D2300/614
摘要： A method of forming a turbine component that includes a ceramic matrix composite-ceramic insulation composite with a vapor resistant layer is disclosed. The method includes providing an inner tool and an outer tool, wherein the inner and outer tools define a mold for forming a turbine component. A vapor resistant layer can be applied to the inner tool, and a ceramic insulation layer can be applied over the vapor resistant layer in the mold. The vapor resistant layer and the ceramic insulation layer can be partially fired to form a bisque turbine component, and the outer tool can be removed. The inner tool can include a transitory material. A layer of ceramic matrix composite material can be applied to the outside of the bisque turbine component to form a component, and the component can be fired to form a turbine component.
摘要翻译：公开了一种形成包括具有耐蒸汽层的陶瓷基复合陶瓷绝缘复合材料的涡轮机部件的方法。该方法包括提供内部工具和外部工具，其中内部和外部工具限定用于形成涡轮机部件的模具。可以将耐蒸汽层施加到内部工具，并且可以在模具中的耐蒸汽层上施加陶瓷绝缘层。可以将耐蒸汽层和陶瓷绝缘层部分地烧制以形成一个等压涡轮机部件，并且可以去除外部工具。内部工具可以包括短暂的材料。可以将一层陶瓷基复合材料施加到等压涡轮机部件的外部以形成部件，并且该部件可以被烧制以形成涡轮机部件。

93. 发明申请

US20100019412A1 METHOD OF MANUFACTURING A THERMAL INSULATION ARTICLE 有权
标题翻译：制造绝热制品的方法
公开(公告)号：US20100019412A1
公开(公告)日：2010-01-28
申请号：US12177623
申请日：2008-07-22
申请人： Jay E. Lane , Gary B. Merrill
发明人： Jay E. Lane , Gary B. Merrill
IPC分类号： B28B3/00
CPC分类号： B28B21/20 , B28B23/00 , F23R3/007 , F23R2900/00018
摘要： A method of manufacturing a thermal insulation article may include positioning, between opposing mold walls, a first layer comprising a ceramic matrix composite (CMC) material and a second layer comprising a plurality of tiles. The method may further include moving the opposing mold walls together to compress together the first and second layers, and curing the compressed together first and second layers to produce the thermal insulation article.
摘要翻译：制造隔热制品的方法可以包括在相对的模具壁之间定位包括陶瓷基质复合材料（CMC）材料的第一层和包括多个瓷砖的第二层。该方法还可以包括将相对的模具壁移动到一起以将第一和第二层压缩在一起，以及将压缩在一起的第一和第二层固化以产生绝热制品。

94. 发明授权

US07648605B2 Process for applying a thermal barrier coating to a ceramic matrix composite 有权
标题翻译：将热障涂层施加到陶瓷基复合材料的方法
公开(公告)号：US07648605B2
公开(公告)日：2010-01-19
申请号：US11804140
申请日：2007-05-17
申请人： Gary B. Merrill , Thomas B. Jackson
发明人： Gary B. Merrill , Thomas B. Jackson
IPC分类号： G03B29/00 , B32B27/00 , B32B18/00
CPC分类号： B32B38/0036 , B32B2038/0044 , B32B2307/304 , B32B2309/105 , B32B2311/24 , B32B2315/02 , C04B35/111 , C04B37/005 , C04B37/006 , C04B2235/3217 , C04B2235/444 , C04B2235/5436 , C04B2235/5445 , C04B2235/5472 , C04B2237/064 , C04B2237/38 , C04B2237/72 , C04B2237/74 , Y10T428/24033 , Y10T428/252
摘要： A method of bonding an insulation layer (26) to a CMC layer (22) by applying a compliant joining layer (24) between them in a series of steps (52-70) effective to bond the layers (22, 24, 26) with reduced differential shrinkage stresses during firing and reduced residual stresses. The CMC layer (22) and the compliant layer (24) may each be fired to an intermediate stage prior to applying the next layer (24 and 26 respectively), such that the compliant layer (24) has a remaining amount of curing shrinkage between that of the CMC layer (22) and the insulating layer (26) during a final firing stage. The insulation layer (26) may be a friable graded insulation (26F) cast as a composite of hollow ceramic spheres (26S) in a ceramic matrix (26M). The compliant layer (24) may form a checkerboard of cracks (72) oriented generally perpendicular to the layer surface that function to relax stress. The cracks define columns (74) of material that form a bond at opposed ends to the CMC layer and to the insulation respectively.
摘要翻译：一种通过在有效地结合层（22,24,26）的一系列步骤（52-70）中施加柔性接合层（24）而将绝缘层（26）结合到CMC层（22）的方法，在焙烧期间具有降低的差异收缩应力和减小的残余应力。在施加下一层（分别为24和26）之前，CMC层（22）和顺应层（24）可以各自被烧制到中间阶段，使得顺应层（24）具有在 CMC层（22）和绝缘层（26）的最终焙烧阶段。绝缘层（26）可以是作为陶瓷基体（26M）中的中空陶瓷球（26S）的复合材料浇注的易碎梯度绝缘层（26F）。顺应层（24）可以形成通常垂直于层表面定向起作用以松弛应力的裂纹（72）的棋盘。裂纹定义了在CMC层和绝缘体的相对端形成结合的材料的柱（74）。

95. 发明申请

US20090081033A1 Stacked Lamellae Ceramic Gas Turbine Ring Segment Component 有权
标题翻译：堆叠薄膜陶瓷燃气轮机环段组件
公开(公告)号：US20090081033A1
公开(公告)日：2009-03-26
申请号：US11928407
申请日：2007-10-30
申请人： Anthony L. Schiavo , Gary B. Merrill , Thomas B. Jackson , Todd Willis
发明人： Anthony L. Schiavo , Gary B. Merrill , Thomas B. Jackson , Todd Willis
IPC分类号： F01D9/04
CPC分类号： F01D11/08 , F05D2240/11
摘要： A gas turbine ring segment (10) for use in gas turbine engines made from a ceramic matrix composite (CMC) material is disclosed. The ring segment includes a stacked multiplicity of CMC thin-sheet lamellae (25a, 25b) each comprising a peripheral surface collectively defining a cross-section profile of the ring segment. The lamellae collectively define a channel (11) formed in the center thereof for receiving a bow-tie member (27). The bow-tie member is disposed in the channel for holding together the stacked lamellae in a through thickness direction, and the in-plane strength of the bow-tie member is perpendicular to the in-plane strength of the lamellae. A stem portion (33) of the assembly may be further secured with a wrap (38) of CMC ribbon.
摘要翻译：公开了一种用于由陶瓷基体复合材料（CMC）材料制成的燃气涡轮发动机的燃气轮机环段（10）。环段包括堆叠的多个CMC薄片薄片（25a，25b），每个薄片片层包括共同限定环形部分的横截面轮廓的外围表面。薄片共同限定形成在其中心的通道（11），用于接收弓形构件（27）。蝴蝶结构件设置在通道中，用于将堆叠的薄片沿着厚度方向保持在一起，并且蝴蝶结构件的面内强度垂直于薄片的面内强度。组件的杆部分（33）可以用CMC带的包裹物（38）进一步固定。

96. 发明申请

US20080284059A1 Process for applying a thermal barrier coating to a ceramic matrix composite 有权
标题翻译：将热障涂层施加到陶瓷基复合材料的方法
公开(公告)号：US20080284059A1
公开(公告)日：2008-11-20
申请号：US11804140
申请日：2007-05-17
申请人： Gary B. Merrill , Thomas B. Jackson
发明人： Gary B. Merrill , Thomas B. Jackson
IPC分类号： B32B37/00
CPC分类号： B32B38/0036 , B32B2038/0044 , B32B2307/304 , B32B2309/105 , B32B2311/24 , B32B2315/02 , C04B35/111 , C04B37/005 , C04B37/006 , C04B2235/3217 , C04B2235/444 , C04B2235/5436 , C04B2235/5445 , C04B2235/5472 , C04B2237/064 , C04B2237/38 , C04B2237/72 , C04B2237/74 , Y10T428/24033 , Y10T428/252
摘要： A method of bonding an insulation layer (26) to a CMC layer (22) by applying a compliant joining layer (24) between them in a series of steps (52-70) effective to bond the layers (22, 24, 26) with reduced differential shrinkage stresses during firing and reduced residual stresses. The CMC layer (22) and the compliant layer (24) may each be fired to an intermediate stage prior to applying the next layer (24 and 26 respectively), such that the compliant layer (24) has a remaining amount of curing shrinkage between that of the CMC layer (22) and the insulating layer (26) during a final firing stage. The insulation layer (26) may be a friable graded insulation (26F) cast as a composite of hollow ceramic spheres (26S) in a ceramic matrix (26M). The compliant layer (24) may form a checkerboard of cracks (72) oriented generally perpendicular to the layer surface that function to relax stress. The cracks define columns (74) of material that form a bond at opposed ends to the CMC layer and to the insulation respectively.
摘要翻译：一种通过在有效地粘合层（22,24,26）的一系列步骤（52-70）中施加柔性连接层（24）将绝缘层（26）粘合到CMC层（22）上的方法，在焙烧期间具有降低的差异收缩应力和减小的残余应力。在施加下一层（分别为24和26）之前，CMC层（22）和顺应层（24）可以各自被烧制到中间阶段，使得顺应层（24）具有在 CMC层（22）和绝缘层（26）的最终焙烧阶段。绝缘层（26）可以是作为陶瓷基体（26M）中的中空陶瓷球（26S）的复合材料的易碎梯度隔离层（26F）。顺应层（24）可以形成通常垂直于层表面定向起作用以松弛应力的裂纹（72）的棋盘。裂纹定义了在CMC层和绝缘体的相对端形成结合的材料的柱（74）。

97. 发明申请

US20080280101A1 Patterned reduction of surface area for abradability 有权
标题翻译：图形化的表面积减少磨损性
公开(公告)号：US20080280101A1
公开(公告)日：2008-11-13
申请号：US11800801
申请日：2007-05-07
申请人： Jay A. Morrison , Jay E. Lane , Gary B. Merrill
发明人： Jay A. Morrison , Jay E. Lane , Gary B. Merrill
IPC分类号： B32B3/30
CPC分类号： F01D11/122 , B32B3/30 , F05D2250/18 , F05D2250/70 , F05D2300/21 , F05D2300/603 , Y10T428/24355
摘要： A gas turbine component (20) with a layer of ceramic material (22) defining a wear surface (21), in which an array of cross-shaped depressions (26A, 26B) formed in the wear surface (21) define a continuous labyrinth of orthogonal walls (28, 30) of the ceramic material, and reduce the area of the wear surface (21) by about 50%. Within a representative area (36) of the wear surface (21), the depressions (26A, 26B) provide a ratio of a lineal sum of depression perimeters (27) divided by the representative area (36) of the wear surface of least 0.9 per unit of measurement for improved abradability characteristics of the wear surface (21).
摘要翻译：具有限定磨损表面（21）的陶瓷材料层（22）的燃气轮机部件（20），其中形成在磨损表面（21）中的十字形凹陷（26A，26B）阵列限定了一个陶瓷材料的正交壁（28,30）的连续迷宫，并且将磨损表面（21）的面积减小约50％。在磨损表面（21）的代表性区域（36）内，凹陷（26A，26B）提供凹陷周长（27）的直线和除以磨损表面的代表区域（36）每单位测量值最小为0.9，以改善磨损表面（21）的磨损性能。

98. 发明申请

US20080207075A1 Optimized fabric lay-up for improved ceramic matrix composites 审中-公开
标题翻译：用于改进陶瓷基复合材料的优化织物叠层
公开(公告)号：US20080207075A1
公开(公告)日：2008-08-28
申请号：US11709699
申请日：2007-02-22
申请人： Gary B. Merrill , Jay E. Lane
发明人： Gary B. Merrill , Jay E. Lane
IPC分类号： B32B18/00
CPC分类号： B32B18/00 , Y10T442/3659
摘要： A ceramic matrix composite (CMC) is constructed from ceramic fabric sheets and a ceramic matrix to yield matrix rich zone of reduced dimensions between fabric sheets. This reduction in dimension decreases the occurrence of delamination between the fabric sheets. The fabric is optimized to reduce the size of matrix rich zones in the composite by increasing the number of fabric plies in a given thickness of composite.
摘要翻译：陶瓷基体复合材料（CMC）由陶瓷织物片和陶瓷基体构成，以在织物片之间产生尺寸减小的基质富集区。尺寸的减小减少了织物片之间的分层的发生。优化该织物以通过增加给定厚度的复合材料中的织物层的数量来减小复合材料中富含基质的区域的尺寸。

99. 发明申请

US20080199661A1 Thermally insulated CMC structure with internal cooling 审中-公开
标题翻译：具有内部冷却的绝热CMC结构
公开(公告)号：US20080199661A1
公开(公告)日：2008-08-21
申请号：US11707191
申请日：2007-02-15
申请人： Douglas A. Keller , Malberto F. Gonzalez , Gary B. Merrill
发明人： Douglas A. Keller , Malberto F. Gonzalez , Gary B. Merrill
IPC分类号： B32B3/20
CPC分类号： F01D5/284 , B32B3/08 , B32B3/30 , B32B5/024 , B32B9/005 , B32B9/047 , B32B18/00 , B32B2262/105 , B32B2307/304 , B32B2605/00 , C04B37/001 , C04B2237/32 , C04B2237/38 , C04B2237/62 , C04B2237/64 , C04B2237/765 , F05D2240/11 , F05D2240/81 , F05D2260/20 , Y10T428/24744
摘要： An insulated CMC structure (20A) formed of a CMC layer (22A), a thermal insulation layer (24A) applied to a front surface (30A) of the CMC layer (22A), and cooling channels (28A) formed along the interface (26A) between the CMC layer and the thermal insulation layer, thus directly cooling the thermally critical area of the interface. Embodiments include cooling channels in direct contact with both layers (FIG. 1); cooling channels in one layer and tangent to the other layer (FIGS. 4, 5 and 9); cooling channels in the CMC layer with an intervening wall (36D, 36E) that bulges into the thermal insulation layer for improved bonding thereof (FIGS. 6, 7); and cooling channels formed in ceramic tubes (38F of FIG. 8).
摘要翻译：由CMC层（22A），施加到CMC层（22A）的前表面（30A）上的绝热层（24A）和冷却通道（28A）形成的绝缘的CMC结构（20A））沿着CMC层和绝热层之间的界面（26A）形成，从而直接冷却界面的热临界区域。实施例包括与两层直接接触的冷却通道（图1）; 一层冷却通道并与另一层相切（图4，图5和图9）; 在CMC层中的冷却通道具有凸起进入绝热层的中间壁（36D，36E），以改善其粘结（图6,7）。以及形成在陶瓷管（图8的38F）中的冷却通道。

100. 发明授权

US07311790B2 Hybrid structure using ceramic tiles and method of manufacture 有权
标题翻译：使用陶瓷砖的混合结构及其制造方法
公开(公告)号：US07311790B2
公开(公告)日：2007-12-25
申请号：US10767013
申请日：2004-01-29
申请人： Jay A. Morrison , Gary B. Merrill , Michael A. Burke , Jay Edgar Lane , Steven James Vance
发明人： Jay A. Morrison , Gary B. Merrill , Michael A. Burke , Jay Edgar Lane , Steven James Vance
IPC分类号： B32B37/06 , B32B37/14 , B32B38/00 , B32B38/10 , C03B29/00
CPC分类号： B28B19/0053 , B28B21/42 , F05D2300/6033 , F23R3/007
摘要： A hybrid structure (50) and method of manufacturing the same including a structural ceramic matrix composite (CMC) material (42) coated with a layer of ceramic insulating tiles (24). Individual ceramic tiles are attached to a surface (22) of a mold (20). The exterior surface (32) of the tiles may be subjected to a mechanical process such as machining with the mold in place to provide mechanical support for the tiles. A layer of CMC material is then applied to bond the tiles and the CMC material together into a hybrid structure. The mold may include a fugitive material portion (26) to facilitate removal of the mold when the hybrid structure has a complex shape. Tiles located in different regions of the structure may have different compositions and/or dimensions. The gaps between adjacent tiles may be filled from the outside before the CMC material is applied or from the inside after the mold is removed.
摘要翻译：一种混合结构（50）及其制造方法，包括涂覆有陶瓷绝缘砖（24）层的结构陶瓷基复合材料（CMC）材料（42）。单个陶瓷砖附接到模具（20）的表面（22）。瓦片的外表面（32）可以经受机械加工，例如用模具进行机械加工，以为瓦片提供机械支撑。然后施加一层CMC材料以将瓷砖和CMC材料结合在一起成为混合结构。当混合结构具有复杂的形状时，模具可以包括短片材料部分（26），以便于去除模具。位于结构的不同区域的瓷砖可以具有不同的组成和/或尺寸。相邻瓦片之间的间隙可以在CMC材料施加之前从外部填充，或者在模具移除之后从内部填充。

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