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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. 发明授权

US07093359B2 Composite structure formed by CMC-on-insulation process 有权
标题翻译：复合结构由CMC绝缘过程形成
公开(公告)号：US07093359B2
公开(公告)日：2006-08-22
申请号：US10245528
申请日：2002-09-17
申请人： Jay A. Morrison , Gary Brian Merrill , Jay Edgar Lane , Steven C. Butner , Harry A. Albrecht , Scott M. Widrig , Yevgeniy P. Shteyman
发明人： Jay A. Morrison , Gary Brian Merrill , Jay Edgar Lane , Steven C. Butner , Harry A. Albrecht , Scott M. Widrig , Yevgeniy P. Shteyman
IPC分类号： B21K3/04 , B21D53/78 , B23P15/02
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）。

3. 发明授权

US06709230B2 Ceramic matrix composite gas turbine vane 有权
标题翻译：陶瓷基复合燃气轮机叶片
公开(公告)号：US06709230B2
公开(公告)日：2004-03-23
申请号：US10158946
申请日：2002-05-31
申请人： Jay A. Morrison , Chris Campbell , Gary Brian Merrill , Jay Edgar Lane , Daniel George Thompson , Harry A. Albrecht , Yevgeniy P. Shteyman
发明人： Jay A. Morrison , Chris Campbell , Gary Brian Merrill , Jay Edgar Lane , Daniel George Thompson , Harry A. Albrecht , Yevgeniy P. Shteyman
IPC分类号： F01D904
CPC分类号： F01D5/189 , F01D5/282 , F01D5/284 , F01D5/288 , F05D2300/50212 , F05D2300/6033 , Y02T50/672 , Y02T50/673 , Y02T50/676 , Y10T428/252 , Y10T428/257
摘要： A hybrid vane (50) for a gas turbine engine having a ceramic matrix composite (CMC) airfoil member (52) bonded to a substantially solid core member (54). The airfoil member and core member are cooled by a cooling fluid (58) passing through cooling passages (56) formed in the core member. The airfoil member is cooled by conductive heat transfer through the bond ((70) between the core member and the airfoil member and by convective heat transfer at the surface directly exposed to the cooling fluid. A layer of insulation (72) bonded to the external surface of the airfoil member provides both the desired outer aerodynamic contour and reduces the amount of cooling fluid required to maintain the structural integrity of the airfoil member. Each member of the hybrid vane is formulated to have a coefficient of thermal expansion and elastic modulus that will minimize thermal stress during fabrication and during turbine engine operation.
摘要翻译：一种用于燃气涡轮发动机的混合叶片（50），其具有结合到基本上实心的芯构件（54）上的陶瓷基体复合（CMC）翼型件（52）。机翼构件和芯构件通过穿过形成在芯构件中的冷却通道（56）的冷却流体（58）来冷却。翼型部件通过导电传热通过芯部件和翼型部件之间的（70）进行冷却，并通过直接暴露于冷却流体的表面上的对流传热来冷却。翼型件的表面提供所需的外部空气动力学轮廓并且减少维持翼型构件的结构完整性所需的冷却流体的量。混合叶片的每个构件被配制成具有热膨胀系数和弹性模量，在制造期间和涡轮发动机运行期间最小化热应力。

4. 发明授权

US07402347B2 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：US07402347B2
公开(公告)日：2008-07-22
申请号：US11031796
申请日：2005-01-07
申请人： Jay A. Morrison , Daniel G. Thompson , Gary B. Merrill , Jay Edgar Lane
发明人： Jay A. Morrison , Daniel G. Thompson , Gary B. Merrill , Jay Edgar Lane
IPC分类号： B64C11/16 , B64C27/46 , F01D5/14 , B63H27/46
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。

5. 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。

6. 发明授权

US06197424B1 Use of high temperature insulation for ceramic matrix composites in gas turbines 失效
标题翻译：在燃气轮机中使用高温绝缘陶瓷基复合材料
公开(公告)号：US06197424B1
公开(公告)日：2001-03-06
申请号：US09049369
申请日：1998-03-27
申请人： Jay Alan Morrison , Gary Brian Merrill , Evan McNeil Ludeman , Jay Edgar Lane
发明人： Jay Alan Morrison , Gary Brian Merrill , Evan McNeil Ludeman , Jay Edgar Lane
IPC分类号： B32B516
CPC分类号： F01D11/12 , C04B28/344 , C04B38/08 , C04B2111/00482 , C04B2111/28 , Y02T50/67 , Y02T50/672 , Y10T428/2982 , C04B14/30 , C04B14/301 , C04B38/0038
摘要： A ceramic composition for insulating components, made of ceramic matrix composites, of gas turbines is provided. The composition comprises a plurality of hollow oxide-based spheres of various dimensions, a phosphate binder, and at least one oxide filler powder, whereby the phosphate binder partially fills gaps between the spheres and the filler powders. The spheres are situated in the phosphate binder and the filler powders such that each sphere is in contact with at least one other sphere and the arrangement of spheres is such that the composition is dimensionally stable and chemically stable at a temperature of approximately 1600° C. A stationary vane of a gas turbine comprising the composition of the present invention bonded to the outer surface of the vane is provided. A combustor comprising the composition bonded to the inner surface of the combustor is provided. A transition duct comprising the insulating coating bonded to the inner surface of the transition is provided. Because of abradable properties of the composition, a gas turbine blade tip seal comprising the composition also is provided. The composition is bonded to the inside surface of a shroud so that a blade tip carves grooves in the composition so as to create a customized seal for the turbine blade tip.
摘要翻译：提供了一种陶瓷组合物，用于燃气轮机的由陶瓷基复合材料制成的绝缘部件。该组合物包括多个尺寸为多个中空氧化物基球体，磷酸盐粘合剂和至少一种氧化物填料粉末，由此磷酸盐粘合剂部分地填充球体和填料粉末之间的间隙。球体位于磷酸盐粘合剂和填料粉末中，使得每个球体与至少一个其它球体接触，并且球体的排列使得组合物在约1600℃的温度下尺寸稳定和化学稳定。提供了一种燃气轮机的固定叶片，其包括结合到叶片的外表面的本发明的组合物。提供了包含结合到燃烧器的内表面的组合物的燃烧器。提供了一种过渡管，其包括结合到过渡的内表面的绝缘涂层。由于组合物的耐磨特性，还提供了包含该组合物的燃气轮机叶片尖端密封件。组合物结合到护罩的内表面，使得叶片尖端在组合物中雕刻凹槽，以便为涡轮叶片尖端产生定制的密封。

7. 发明授权

US5854154A Process of making oxide ceramic composites 失效
标题翻译：制作氧化陶瓷复合材料的工艺
公开(公告)号：US5854154A
公开(公告)日：1998-12-29
申请号：US847248
申请日：1997-05-01
申请人： Kenneth Charles Radford , Jay Edgar Lane
发明人： Kenneth Charles Radford , Jay Edgar Lane
IPC分类号： C04B35/624 , C04B35/65 , C04B35/80
CPC分类号： C04B35/803 , C04B35/624 , C04B35/65
摘要： An oxide ceramic composite suitable for fabricating components of combustion turbines and similar high temperature environments. The composite is fabricated by dispersing metal particles in a fiber preform and infiltrating the fiber preform with sol-gel matrix precursor material. Alternatively, the metal particles are mixed into the sol-gel matrix precursor material and the preform is infiltrated with the mixture. Later in the fabrication process, the metal particles oxidize and become oxidized metal when the sol-gel matrix precursor material is sintered. The oxidized metal has more volume and mass than the metal particles. As a result, the oxidized metal contributes to increasing the density of the composite so that it is suitable for use in combustion turbines and similar high temperature environments.
摘要翻译：适用于制造燃气轮机组件和类似高温环境的氧化物陶瓷复合材料。通过将金属颗粒分散在纤维预成型体中并用溶胶 - 凝胶基质前体材料渗透纤维预制件来制造复合材料。或者，将金属颗粒混合到溶胶 - 凝胶基质前体材料中，并用预混合物渗透预型体。在制造过程中，当溶胶 - 凝胶基体前体材料烧结时，金属颗粒氧化并变成氧化金属。氧化金属比金属颗粒具有更多的体积和质量。结果，氧化金属有助于提高复合材料的密度，使其适用于燃气轮机和类似的高温环境。

8. 发明授权

US06884384B2 Method for making a high temperature erosion resistant material containing compacted hollow geometric shapes 有权
标题翻译：制造具有压实中空几何形状的耐高温侵蚀材料的方法
公开(公告)号：US06884384B2
公开(公告)日：2005-04-26
申请号：US09965558
申请日：2001-09-27
申请人： Gary Brian Merrill , Jay Edgar Lane , Curtis Gosik
发明人： Gary Brian Merrill , Jay Edgar Lane , Curtis Gosik
IPC分类号： B28B1/26 , B28B19/00 , C04B35/63 , C04B38/08 , F01D11/12 , F23R3/00
CPC分类号： C04B38/08 , B28B1/265 , B28B19/003 , C04B35/6303 , C04B35/6309 , C04B2111/00612 , C04B2235/3205 , C04B2235/3217 , C04B2235/3222 , C04B2235/3224 , C04B2235/3225 , C04B2235/3229 , C04B2235/3244 , C04B2235/3248 , C04B2235/3418 , C04B2235/3463 , C04B2235/3826 , C04B2235/3839 , C04B2235/3873 , C04B2235/3886 , C04B2235/402 , C04B2235/528 , F01D11/122 , F05D2300/502 , F23M2900/05004 , F23R3/007 , Y02T50/67 , Y02T50/672 , C04B35/00 , C04B40/006 , C04B40/0071
摘要： A method for making a thermal insulating material includes the steps of: providing a chamber, placing hollow geometric shapes in the chamber, closing the chamber, evacuating air from the chamber, feeding a slurry into an adjacent slurry chamber, pressurizing the slurry chamber and forcing the slurry in to the sphere chamber around the spheres against a fibrous material adjacent a side wall of the sphere chamber. The fibrous material allows capillary wicking of the liquid from the slurry around the spheres. Due to this pressure the spheres and slurry are semi dried into a green state. The material in its green state green is subsequently dried and fired to form the insulating material.
摘要翻译：制造隔热材料的方法包括以下步骤：提供一个室，将空心几何形状放置在该室中，关闭该室，从该室中排出空气，将浆料送入相邻的浆液室，对浆料室加压并迫使浆料在球体周围围绕球体抵靠邻近球体室侧壁的纤维材料。纤维材料允许来自球体周围的浆液的液体的毛细管芯吸收。由于这种压力，球体和浆料被半干燥成绿色状态。随后将其绿色状态的绿色材料干燥并烧制以形成绝缘材料。

9. 发明授权

US06977060B1 Method for making a high temperature erosion resistant coating and material containing compacted hollow geometric shapes 有权
标题翻译：制造耐高温侵蚀涂层的方法和含有压实中空几何形状的材料
公开(公告)号：US06977060B1
公开(公告)日：2005-12-20
申请号：US09536742
申请日：2000-03-28
申请人： Gary Brian Merrill , Jay Edgar Lane
发明人： Gary Brian Merrill , Jay Edgar Lane
IPC分类号： C04B38/08 , 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。

10. 发明授权

US06929852B2 Protective overlayer for ceramics 有权
标题翻译：陶瓷保护层
公开(公告)号：US06929852B2
公开(公告)日：2005-08-16
申请号：US10214784
申请日：2002-08-08
申请人： Jay Edgar Lane , Gary Brian Merrill
发明人： Jay Edgar Lane , Gary Brian Merrill
IPC分类号： C04B41/50 , C04B41/52 , C04B41/87 , C04B41/89 , F01D5/28 , B32B9/04
CPC分类号： C04B41/009 , C04B41/5031 , C04B41/52 , C04B41/87 , C04B41/89 , F01D5/288 , F05D2230/90 , F05D2300/611 , Y10T428/249953 , Y10T428/25 , C04B41/4582 , C04B41/5024 , C04B41/5048 , C04B41/522 , C04B20/002 , C04B41/5037 , C04B41/5092 , C04B35/18 , C04B35/185 , C04B35/565 , C04B35/584 , C04B35/803 , C04B35/481
摘要： An alumina comprising composition protective overlayer (20) for protecting a ceramic matrix composite material (12) from a high temperature, moisture-containing environment. Alumina may be used as a protective overlayer to protect an underlying mullite layer to temperatures in excess of 1,500° C. The coating may have porosity of greater than 15% for improved thermal shock protection. To prevent the ingress of oxygen to an underlying ceramic material, an oxide barrier layer may be optionally disposed between the alumina coating and the ceramic material. Such a protective overlayer may be used for an article having a ceramic oxide or non-oxide substrate.
摘要翻译：一种氧化铝，其包括用于保护陶瓷基质复合材料（12）免受高温，含湿气体环境的组合物保护性覆层（20）。氧化铝可用作保护性覆层，以将下面的莫来石层保护到超过1500℃的温度。涂层可具有大于15％的孔隙率，以改善热冲击保护。为了防止氧气进入下面的陶瓷材料，氧化物阻挡层可以任选地设置在氧化铝涂层和陶瓷材料之间。这种保护性覆层可以用于具有陶瓷氧化物或非氧化物基底的制品。

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