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1. 发明申请

US20050076504A1 COMPOSITE STRUCTURE FORMED BY CMC-ON-INSULATION PROCESS 有权
标题翻译： CMC-ON-INSULING工艺制成的复合结构
公开(公告)号：US20050076504A1
公开(公告)日：2005-04-14
申请号：US10245528
申请日：2002-09-17
申请人： Jay A. Morrison , Gary Merrill , Jay Edgar Lane , Steven C. Butner , Harry A. Albrecht , Scott Widrig , Yevgeniy Shteyman
发明人： Jay A. Morrison , Gary Merrill , Jay Edgar Lane , Steven C. Butner , Harry A. Albrecht , Scott Widrig , Yevgeniy Shteyman
IPC分类号： F01D5/28 , F01D9/04 , F01D1/02 , F03B1/04 , F03D1/04
CPC分类号： F01D9/044 , F01D5/282 , F01D5/284 , F05D2230/23 , F05D2240/30 , F05D2300/6033 , Y10T29/49336 , Y10T29/49337 , Y10T29/49339 , Y10T29/49341 , Y10T29/49343 , Y10T29/4998 , Y10T428/249928
摘要： A method of manufacturing a composite structure uses a layer of an insulating material (22) as a mold for forming a substrate of a ceramic matrix composite (CMC) material (24). The insulating material may be formed in the shape of a cylinder (10) with the CMC material wound on an outer surface (14) of the cylinder to form a gas turbine combustor liner (20). Alternatively, the insulating material may be formed in the shape of an airfoil section (32) with the CMC material formed on an inside surface (36) of the insulating material. The airfoil section may be formed of a plurality of halves (42, 44) to facilitate the lay-up of the CMC material onto an easily accessible surface, with the halves then joined together to form the complete composite airfoil. In another embodiment, a box structure (102) defining a hot gas flow passage (98) is manufactured by forming insulating material in the shape of opposed airfoil halves (104) joined at respective opposed ends by platform members (109). A layer of CMC material (107) is then formed on an outside surface of the insulating material. A number of such composite material box structures are then joined together to form a vane ring (100) for a gas turbine engine.
摘要翻译：制造复合结构体的方法使用绝缘材料层（22）作为形成陶瓷基复合材料（CMC）材料（24）的基板的模具。绝缘材料可以形成为圆筒（10）的形状，其中CMC材料缠绕在圆筒的外表面（14）上以形成燃气轮机燃烧器衬套（20）。或者，绝缘材料可以形成为具有形成在绝缘材料的内表面（36）上的CMC材料的翼型部分（32）的形状。翼型部分可以由多个半部（42,44）形成，以便于将CMC材料层叠到易于接近的表面上，其中半部分连接在一起以形成完整的复合翼型件。在另一个实施例中，限定热气流通道（98）的盒结构（102）通过形成由平台构件（109）在相应的相对端连接的相对翼型件（104）的形状的绝缘材料来制造。然后在绝缘材料的外表面上形成一层CMC材料（107）。然后将多个这样的复合材料箱结构连接在一起以形成用于燃气涡轮发动机的叶片环（100）。

2. 发明申请

US20070128043A1 CMC COMPONENT AND METHOD OF FABRICATION 有权
标题翻译： CMC组件和制造方法
公开(公告)号：US20070128043A1
公开(公告)日：2007-06-07
申请号：US11040464
申请日：2005-01-21
申请人： Jay Morrison , Gary Merrill , Steven Vance , Harry Albrecht , Yevgeniy Shteyman
发明人： Jay Morrison , Gary Merrill , Steven Vance , Harry Albrecht , Yevgeniy Shteyman
IPC分类号： F03B3/12
CPC分类号： F01D5/284 , F01D5/147 , F01D5/282 , Y10T29/49337 , Y10T29/49339
摘要： An airfoil (44) formed of a plurality of pre-fired structural CMC panels (46, 48, 50, 52). Each panel is formed to have an open shape having opposed ends (54) that are free to move during the drying, curing and/or firing of the CMC material in order to minimize interlaminar stresses caused by anisotropic sintering shrinkage. The panels are at least partially pre-shrunk prior to being joined together to form the desired structure, such as an airfoil (42) for a gas turbine engine. The panels may be joined together using a backing member (30), using flanged ends (54) and a clamp (56), and/or with a bond material (36), for example.
摘要翻译：由多个预烧结构的CMC板（46,48,50,52）形成的翼型件（44）。每个板形成为具有相对端（54）的开放形状，其在CMC材料的干燥，固化和/或烧制期间自由移动，以便最小化由各向异性烧结收缩引起的层间应力。在连接在一起以形成期望的结构之前，板至少部分地预收缩，例如用于燃气涡轮发动机的翼型件（42）。例如，使用凸缘端部（54）和夹具（56）和/或与粘合材料（36）一起使用背衬构件（30）将面板连接在一起。

3. 发明申请

US20070108670A1 Methods of manufacturing insulated cermaic matrix composite 有权
标题翻译：绝缘皮层复合材料的制造方法
公开(公告)号：US20070108670A1
公开(公告)日：2007-05-17
申请号：US11649061
申请日：2007-01-03
申请人： Gary Merrill , Jay Lane , Steven Butner , Robert Kreutzer , Jay Morrison
发明人： Gary Merrill , Jay Lane , Steven Butner , Robert Kreutzer , Jay Morrison
IPC分类号： C04B33/32 , B28B1/00
CPC分类号： C04B38/085 , B28B11/041 , C04B28/00 , C04B28/18 , C04B28/34 , C04B35/117 , C04B35/18 , C04B35/803 , C04B41/009 , C04B41/5092 , C04B41/85 , C04B2235/3217 , C04B2235/3463 , C04B2235/5228 , C04B2235/528 , C04B2235/5436 , C04B2235/5445 , C04B2235/5472 , C04B2235/616 , Y10T428/249973 , C04B20/0036 , C04B20/004 , C04B14/303 , C04B14/306 , C04B14/324 , C04B14/328 , C04B20/0048 , C04B20/0076 , C04B38/0061 , C04B38/08
摘要： A composite material (10) formed of a ceramic matrix composite (CMC) material (12) protected by a ceramic insulating material (14). The constituent parts of the insulating material are selected to avoid degradation of the CMC material when the two layers are co-processed. The CMC material is processed to a predetermined state of shrinkage before wet insulating material is applied against the CMC material. The two materials are then co-fired together, with the relative amount of shrinkage between the two materials during the firing step being affected by the amount of pre-shrinkage of the CMC material during the bisque firing step. The shrinkage of the two materials during the co-firing step may be matched to minimize shrinkage stresses, or a predetermined amount of prestress between the materials may be achieved. An aluminum hydroxyl chloride binder material (24) may be used in the insulating material in order to avoid degradation of the fabric (28) of the CMC material during the co-firing step.
摘要翻译：由陶瓷绝缘材料（14）保护的陶瓷基复合材料（CMC）材料（12）形成的复合材料（10）。选择绝缘材料的组成部分以避免当两层被共同处理时CMC材料的劣化。在向CMC材料施加湿绝缘材料之前，将CMC材料加工成预定的收缩状态。然后将两种材料共烧，在焙烧步骤期间两种材料之间的相对收缩量受到在坯料烧结步骤期间CMC材料的预收缩量的影响。可以在共烧步骤期间两种材料的收缩率相匹配以最小化收缩应力，或者可以实现材料之间的预定量的预应力。可以在绝缘材料中使用铝羟基氯化物粘合剂材料（24），以避免在共烧烧步骤期间CMC材料的织物（28）的降解。

4. 发明申请

US20070075455A1 Method of sealing a free edge of a composite material 审中-公开
标题翻译：密封复合材料的自由边缘的方法
公开(公告)号：US20070075455A1
公开(公告)日：2007-04-05
申请号：US11243147
申请日：2005-10-04
申请人： Bonnie Marini , Gary Merrill , Jay Lane
发明人： Bonnie Marini , Gary Merrill , Jay Lane
IPC分类号： B29C45/14 , D04H5/00 , D04H1/00 , B05D3/02 , D04H13/00 , D04H3/00
CPC分类号： C04B41/87 , C04B41/0036 , C04B41/009 , Y10T428/249924 , C04B41/4523 , C04B41/4572 , C04B41/5027 , C04B35/803
摘要： A method of coating an edge surface (30) of an anisotropic ceramic matrix composite material (10) for use in a high temperature environment is disclosed where the edge surface (30) has exposed reinforced fiber layers (20). A laser beam may be used to melt a portion of the ceramic matrix composite material (10) on the edge surface (30) forming a melt layer. The melt layer is retained proximate the edge surface and the laser beam is controlled to form an isotropic protective coating (32, 34) on a portion of the edge surface (30). A method may be used to form a component for use in a high temperature environment that includes directing a laser beam toward a ceramic matrix composite material (10), controlling the laser beam to melt a portion of the ceramic matrix composite material (10) and forming a homogeneous protective coating (32, 34) from a melt layer that exerts compression on at least a portion of the ceramic matrix composite material (10) when the melt layer is cooled. A powder material (35) may be added to a surface of the ceramic matrix composite material (10) selected to melt with the ceramic matrix composite material (10) to improve the wear resistance or hardness of the isotropic protective coating (32, 34).
摘要翻译：公开了一种涂覆用于高温环境的各向异性陶瓷基复合材料（10）的边缘表面（30）的方法，其中边缘表面（30）具有暴露的增强纤维层（20）。可以使用激光束来熔化形成熔体层的边缘表面（30）上的陶瓷基质复合材料（10）的一部分。熔体层保持在边缘表面附近并且激光束被控制以在边缘表面（30）的一部分上形成各向同性的保护涂层（32,34）。可以使用一种方法来形成在高温环境中使用的部件，其包括将激光束引向陶瓷基质复合材料（10），控制激光束熔化陶瓷基质复合材料（10）的一部分和当熔融层被冷却时，从熔融层形成均匀的保护涂层（32,34），所述熔融层在至少一部分陶瓷基复合材料（10）上施加压缩。可以将陶瓷基复合材料（10）的表面添加到陶瓷基复合材料（10）中以与陶瓷基复合材料（10）熔融以提高各向同性保护涂层（32,34）的耐磨性或硬度的粉末材料（35）。

5. 发明申请

US20060121296A1 In-situ formed thermal barrier coating for a ceramic component 有权
标题翻译：用于陶瓷部件的原位形成的热障涂层
公开(公告)号：US20060121296A1
公开(公告)日：2006-06-08
申请号：US11031796
申请日：2005-01-07
申请人： Jay Morrison , Daniel Thompson , Gary Merrill , Jay Lane
发明人： Jay Morrison , Daniel Thompson , Gary Merrill , Jay Lane
IPC分类号： B05D3/02
CPC分类号： F01D5/147 , F04D29/388 , F05D2230/23 , F05D2300/601 , F05D2300/603 , F05D2300/614
摘要： A thermal barrier layer (20) is formed by exposing an oxide ceramic material to a thermal regiment to create a surface heat affected zone effective to protect an underlying structural layer (18) of the material. The heat affected surface layer exhibits a lower strength and higher thermal conductivity than the underlying load-carrying material; however, it retains a sufficiently low thermal conductivity to function as an effective thermal barrier coating. Importantly, because the degraded material retains the same composition and thermal expansion characteristics as the underlying material, the thermal barrier layer remains integrally connected in graded fashion with the underlying material without an interface boundary there between. This invention is particularly advantageous when embodied in an apparatus formed of an oxide-oxide ceramic matrix composite (CMC) material wherein reinforcing fibers (24) are anchored in the underlying load-carrying portion and extend into the non-structural thermal barrier portion to provide support and to function as surface crack arrestors. In one embodiment an airfoil (10) is formed of a stacked plurality of CMC plates having such a heat-affected thermal barrier layer formed thereon.
摘要翻译：通过将氧化物陶瓷材料暴露于热团来形成有效保护材料的下面的结构层（18）的表面热影响区域来形成热障层（20）。受热影响的表层具有比下面的承载材料更低的强度和更高的热导率; 然而，它保持足够低的热导率以用作有效的热障涂层。重要的是，由于降解的材料保持与下面的材料相同的组成和热膨胀特性，所以热屏障层保持与下面的材料以分级方式整体连接，而其间没有界面边界。当本发明体现在由氧化物 - 氧化物陶瓷基质复合材料（CMC）材料形成的装置中时，特别有利的是，其中增强纤维（24）锚固在下面的承载部分并延伸到非结构性热障部分中，以提供支持和作为表面裂纹器。在一个实施例中，翼片（10）由在其上形成有这种受热影响的热阻挡层的多个CMC板堆叠形成。

6. 发明申请

US20060120874A1 Stacked lamellate assembly 有权
标题翻译：堆叠层状组件
公开(公告)号：US20060120874A1
公开(公告)日：2006-06-08
申请号：US11031797
申请日：2005-01-07
申请人： Michael Burke , Jay Morrison , Steven Vance , Daniel Thompson , Vijay Parthasarathy , Gary Merrill , Douglas Keller
发明人： Michael Burke , Jay Morrison , Steven Vance , Daniel Thompson , Vijay Parthasarathy , Gary Merrill , Douglas Keller
IPC分类号： F04D29/38
CPC分类号： F01D5/147 , F01D5/284 , F04D29/388 , F05D2230/23 , F05D2300/601 , F05D2300/603 , F05D2300/614
摘要： A stacked ceramic matrix composite lamellate assembly (10) including shear force bearing structures (48) for resisting relative sliding movement between adjacent lamellae. The shear force bearing structures may take the form of a cross-lamellar stitch (50), a shear pin (62), a warp (90) in the lamellae, a tongue (104) and groove (98) structure, or an inter-lamellar sealing member (112), in various embodiments. Each shear force bearing structure secures a subset of the lamellae, with at least one lamella being common between adjacent subsets in order to secure the entire assembly.
摘要翻译：一种层叠的陶瓷基复合材料层状组件（10），其包括用于抵抗相邻薄片之间的相对滑动运动的剪切力轴承结构（48）。剪切力承载结构可以采取跨层状缝合（50），剪切销（62），薄片中的经线（90），舌状物（104）和凹槽（98）结构的形式， - 绝缘密封件（112）。每个剪切力轴承结构确保薄片的一个子集，其中至少一个薄片在相邻子集之间是共同的，以便固定整个组件。

7. 发明申请

US20060019087A1 Utilization of discontinuous fibers for improving properties of high temperature insulation for ceramic matrix composites 失效
标题翻译：利用不连续纤维改善陶瓷基复合材料高温绝缘性能
公开(公告)号：US20060019087A1
公开(公告)日：2006-01-26
申请号：US11235496
申请日：2005-09-26
申请人： Stefan Mazzola , Gary Merrill
发明人： Stefan Mazzola , Gary Merrill
IPC分类号： B32B5/16 , B32B18/00
CPC分类号： B32B5/22 , B32B5/24 , B32B2262/105 , B32B2307/72 , C04B28/24 , C04B28/34 , C04B35/111 , C04B35/6309 , C04B35/6316 , C04B38/065 , C04B41/009 , C04B41/5092 , C04B41/85 , C04B2111/00405 , C04B2111/00482 , C04B2111/00982 , C04B2235/3217 , C04B2235/3222 , C04B2235/3224 , C04B2235/3225 , C04B2235/3229 , C04B2235/3244 , C04B2235/3463 , C04B2235/3826 , C04B2235/3873 , C04B2235/483 , C04B2235/5224 , C04B2235/5228 , C04B2235/5236 , C04B2235/5244 , C04B2235/526 , C04B2235/5436 , C04B2235/5445 , C04B2235/5472 , C04B2235/94 , C04B2235/9615 , F01D5/288 , F05D2250/241 , F05D2300/2112 , F05D2300/2118 , F05D2300/2261 , F05D2300/2263 , F05D2300/2283 , F05D2300/2284 , F05D2300/50 , F05D2300/502 , F05D2300/603 , F05D2300/614 , F23M2900/05004 , F23R3/007 , Y02T50/67 , Y02T50/672 , Y10T428/249921 , Y10T428/24996 , Y10T428/249971 , Y10T428/249975 , Y10T428/249976 , Y10T428/249981 , Y10T428/249985 , Y10T428/249987 , Y10T428/249999 , Y10T428/25 , Y10T428/252 , C04B14/4618 , C04B14/4687 , C04B38/08 , C04B38/068 , C04B38/067 , C04B20/004 , C04B41/4582 , C04B41/4596 , C04B41/5025 , C04B35/80
摘要： An insulating material 14 adapted for use in a high temperature environment for coating a turbine component is provided. The insulating material comprises a plurality of geometric shapes 18. The insulating material further comprises a binder for binding together the geometric shapes. A plurality of discontinuous fibers is added to the binder. The discontinuous fibers are adapted to controllably affect one or more properties of the insulating material. For example, non-fugitive chopped fibers 50 may be added to affect a tensile strength property of the insulating material, and fugitive chopped fibers 52 may be added to affect a density property of the insulating material.
摘要翻译：提供一种适于在用于涂覆涡轮部件的高温环境中使用的绝缘材料14。绝缘材料包括多个几何形状18。绝缘材料还包括用于将几何形状结合在一起的粘合剂。将许多不连续纤维加入到粘合剂中。不连续纤维适于可控制地影响绝缘材料的一个或多个特性。例如，可以加入非脆性短切纤维50以影响绝缘材料的拉伸强度性质，并且可以加入短暂的短切纤维52以影响绝缘材料的密度特性。

8. 发明申请

US20070237667A1 High temperature erosion resistant coating and material containing compacted hollow geometric shapes 审中-公开
标题翻译：耐高温侵蚀涂层和含有压实中空几何形状的材料
公开(公告)号：US20070237667A1
公开(公告)日：2007-10-11
申请号：US11235494
申请日：2005-09-26
申请人： Gary Merrill , Jay Lane
发明人： Gary Merrill , Jay Lane
IPC分类号： B22F7/00
CPC分类号： C04B38/08
摘要： A method for making a material system includes the steps of: providing a chamber, placing hollow geometric shapes in the chamber, closing the chamber, evacuating air from the chamber, feeding a binder for the shapes into the evacuated chamber to impregnate the geometric shapes, drying the binder permeated geometric shapes, and heating the hollow shapes and binder to provide a unitary, sintered material system.
摘要翻译：一种用于制造材料系统的方法包括以下步骤：提供一个室，将空心几何形状放置在室中，关闭室，从室排出空气，将形状的粘合剂供入抽真空室以浸渍几何形状，干燥粘合剂渗透的几何形状，并加热中空形状和粘合剂以提供一体的烧结材料体系。

9. 发明申请

US20060211564A1 Ceramic matrix composite utilizing partially stabilized fibers 有权
标题翻译：采用部分稳定纤维的陶瓷基复合材料
公开(公告)号：US20060211564A1
公开(公告)日：2006-09-21
申请号：US11082104
申请日：2005-03-16
申请人： Gary Merrill
发明人： Gary Merrill
IPC分类号： C04B35/80
CPC分类号： C04B35/803 , C04B35/117 , C04B2235/5228 , F01D5/282 , F01D5/284 , F23R3/007
摘要： A green body ceramic matrix composite material (30) is formed using ceramic fibers (32) in an intermediate state disposed in a green body ceramic matrix material (34). The fibers may be in either a dry but unfired (green) condition or in a partially fired condition. Selective control of the degree of pre-firing (pre-shrinkage) of the fibers may be used to control the level of residual stresses within the resulting refractory material resulting from differential shrinkage of the fibers and the matrix material during processing of the composite material.
摘要翻译：使用设置在生坯陶瓷基体材料（34）中的中间状态的陶瓷纤维（32）形成生坯体陶瓷基复合材料（30）。纤维可能处于干燥但未燃烧（绿色）状态或部分烧制状态。纤维的预焙烧（预收缩）程度的选择性控制可用于控制在复合材料的加工期间由于纤维和基体材料的不同收缩而导致的所得耐火材料内的残余应力水平。

10. 发明申请

US20050167878A1 Method of manufacturing a hybrid structure 失效
标题翻译：制造混合结构的方法
公开(公告)号：US20050167878A1
公开(公告)日：2005-08-04
申请号：US10767012
申请日：2004-01-29
申请人： Jay Morrison , Gary Merrill , Steven Vance , Michael Burke
发明人： Jay Morrison , Gary Merrill , Steven Vance , Michael Burke
IPC分类号： B28B7/34 , B28B11/08 , B28B19/00 , B29C33/76 , B29C39/02 , B29C39/12
CPC分类号： B28B7/342 , B28B11/08 , B28B19/00 , C04B2235/6028 , F05D2300/6033 , Y10S264/44
摘要： A method of manufacturing a hybrid structure (100) having a layer of CMC material (28) defining an interior passageway (24) and a layer of ceramic insulating material (18) lining the passageway. The method includes the step of casting the insulating material to a first thickness required for effective casting but in excess of a desired second thickness for use of the hybrid structure. An inner mold (14) defining a net shape desired for the passageway remains in place after the casting step to mechanically support the insulating material during a machining process used to reduce the thickness of the insulating material from the as-cast first thickness to the desired second thickness. The inner mold also provides support as the CMC material is deposited onto the insulating material. The inner mold may include a fugitive material portion (20) to facilitate its removal after the CMC material is formed.
摘要翻译：一种制造具有限定内部通道（24）的CMC材料层（28）和衬套通道的陶瓷绝缘材料层（18）的混合结构（100）的方法。该方法包括将绝缘材料浇铸到有效铸造所需的第一厚度但超过所需的第二厚度以用于混合结构的步骤。限定通道所需的净形状的内模（14）在铸造步骤之后保持就位，以在用于将绝缘材料的厚度从铸造第一厚度减小到期望的机械加工过程期间机械地支撑绝缘材料第二厚度。当CMC材料沉积到绝缘材料上时，内模还提供支撑。内部模具可以包括短暂材料部分（20），以便在形成CMC材料之后便于其移除。

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