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1. 发明授权

US06648597B1 Ceramic matrix composite turbine vane 有权
标题翻译：陶瓷基复合涡轮叶片
公开(公告)号：US06648597B1
公开(公告)日：2003-11-18
申请号：US10158966
申请日：2002-05-31
申请人： Scott M. Widrig , Jay Morrison , Harry A. Albrecht , Yevgeniy Shteyman , Steven C. Butner
发明人： Scott M. Widrig , Jay Morrison , Harry A. Albrecht , Yevgeniy Shteyman , Steven C. Butner
IPC分类号： F01D904
CPC分类号： C04B37/001 , C04B37/005 , C04B2237/06 , C04B2237/068 , C04B2237/341 , C04B2237/343 , C04B2237/365 , C04B2237/38 , C04B2237/61 , C04B2237/765 , C04B2237/80 , C04B2237/84 , F01D5/284 , F01D9/044 , F05D2230/22 , F05D2300/6033
摘要： A ceramic matrix composite material (CMC) vane for a gas turbine engine wherein the airfoil member (12) and the platform member (14) are formed separately and are then bonded together to form an integral vane component (10). Airfoil member and the platform member may be bonded together by an adhesive (20) after being fully cured. Alternatively, respective joint surfaces (16, 18) of the green body state airfoil member and platform member may be co-fired together to form a sinter bond (30). A mechanical fastener (38) and/or a CMC doubler (42) may be utilized to reinforce the bonded joint (40). A matrix infiltration process (50) may be used to create or to further strengthen the bond.
摘要翻译：一种用于燃气涡轮发动机的陶瓷基体复合材料（CMC）叶片，其中所述翼型件（12）和所述平台构件（14）分别形成，然后结合在一起以形成一体式叶片部件（10）。在完全固化之后，翼型构件和平台构件可以通过粘合剂（20）结合在一起。或者，可以将生坯状态翼型构件和平台构件的各个接合面（16,18）共烧在一起形成烧结层（30）。机械紧固件（38）和/或CMC倍增器（42）可用于加强接合接头（40）。矩阵渗透过程（50）可用于产生或进一步加强粘结。

2. 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）。

3. 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）。

4. 发明授权

US06746755B2 Ceramic matrix composite structure having integral cooling passages and method of manufacture 有权
标题翻译：具有集成冷却通道的陶瓷基复合结构及其制造方法
公开(公告)号：US06746755B2
公开(公告)日：2004-06-08
申请号：US09962733
申请日：2001-09-24
申请人： Jay Morrison , Steven C. Butner , Christian X. Campbell , Harry A. Albrecht , Yevgeuiy Shteyman
发明人： Jay Morrison , Steven C. Butner , Christian X. Campbell , Harry A. Albrecht , Yevgeuiy Shteyman
IPC分类号： B32B300
CPC分类号： B32B18/00 , B32B3/18 , B32B2315/02 , C04B35/645 , C04B35/80 , C04B38/0003 , C04B2111/00612 , C04B2235/6028 , C04B2235/6581 , C04B2237/341 , C04B2237/343 , C04B2237/365 , C04B2237/368 , C04B2237/38 , C04B2237/56 , C04B2237/62 , C04B2237/66 , C04B2237/704 , C04B2237/76 , F01D5/187 , F01D5/282 , Y10T428/24562 , Y10T428/24661 , Y10T428/24744 , C04B38/0645
摘要： A multi-layer ceramic matrix composite structure (40) having a plurality of fiber-reinforced cooling passages (42) formed therein. The cooling passages are formed by the removal of a fugitive material (24). The fugitive material is part of a wrapped fugitive material structure (28) containing a layer of reinforcing ceramic fibers (26) that is used to lay-up the multi-layer structure. An intermediate layer of ceramic fabric 56 may be placed alternately over and under the wrapped fugitive material structure to separate the cooling passages into alternating upper (54) and lower (52) cooling passages. The transversely oriented fibers surrounding the cooling passages serve to increase the interlaminar strength of the structure when compared to prior art designs. An airfoil member (112) incorporating such reinforced integral cooling passages (120) is provided.
摘要翻译：一种多层陶瓷基复合结构（40），其中形成有多个纤维增强的冷却通道（42）。冷却通道是通过去除缓冲材料（24）形成的。短暂的材料是包裹的缓冲材料结构（28）的一部分，其包含用于堆叠多层结构的增强陶瓷纤维层（26）。陶瓷织物56的中间层可以交替地放置在缠绕的缓冲材料结构之上和之下，以将冷却通道分离成交替的上部（54）和下部（52）冷却通道。与现有技术的设计相比，围绕冷却通道的横向取向的纤维用于增加结构的层间强度。提供了包括这种加强的整体冷却通道（120）的翼型件（112）。

5. 发明授权

US07179524B2 Insulated ceramic matrix composite and method of manufacturing 有权
标题翻译：绝缘陶瓷基复合材料及其制造方法
公开(公告)号：US07179524B2
公开(公告)日：2007-02-20
申请号：US10667264
申请日：2003-09-19
申请人： Gary B. Merrill , Jay E. Lane , Steven C. Butner , Robert Kreutzer , Jay A. Morrison
发明人： Gary B. Merrill , Jay E. Lane , Steven C. Butner , Robert Kreutzer , Jay A. Morrison
IPC分类号： B32B3/00
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。

6. 发明授权

US5702761A Surface protection of porous ceramic bodies 失效
标题翻译：多孔陶瓷体的表面保护
公开(公告)号：US5702761A
公开(公告)日：1997-12-30
申请号：US235369
申请日：1994-04-29
申请人： Robert A. DiChiara, Jr. , Steven C. Butner
发明人： Robert A. DiChiara, Jr. , Steven C. Butner
IPC分类号： C04B41/50 , B05D7/22
CPC分类号： C04B41/009 , C04B41/5027 , C04B2111/00982
摘要： A surface of a porous ceramic body is protected by binding ceramic particles entirely within the subsurface porosity of the body adjacent to the surface but not present as a separately identifiable surface layer. To produce such a protective layer, a slurry of a mixture of a ceramic powder and a silica-containing binding agent is first prepared. The slurry is impregnated into the surface of the body so that all of the slurry enters the porosity of the body and substantially none of the slurry resides on the surface. The slurry is dried in place, and the residual solids are fired to bind the ceramic powder to the interior walls of the porosity. Drying and firing can be accomplished at intermediate temperatures of about 700.degree.-1000.degree. F. using heat lamps, so that the surface protection can be accomplished without removing the ceramic body from a larger structure.
摘要翻译：多孔陶瓷体的表面通过将陶瓷颗粒完全结合在与表面相邻的本体的地下孔隙中而不作为单独可识别的表面层而被保护。为了制备这样的保护层，首先制备陶瓷粉末和含二氧化硅的粘合剂的混合物的浆料。将浆料浸渍到主体的表面中，使得所有的浆料都进入到主体的孔隙中，并且基本上没有浆料驻留在表面上。将浆料干燥在适当的位置，并且将残留的固体烧制以将陶瓷粉末结合到孔隙的内壁。干燥和焙烧可以在约700°-1000°F的中间温度下使用加热灯完成，从而可以在不从较大结构中去除陶瓷体的情况下实现表面保护。

7. 发明申请

US20100119807A1 CMC WITH MULTIPLE MATRIX PHASES SEPARATED BY DIFFUSION BARRIER 有权
标题翻译：具有由扩散障碍物分离的多个矩阵相位的CMC
公开(公告)号：US20100119807A1
公开(公告)日：2010-05-13
申请号：US11489855
申请日：2006-07-20
申请人： Jay E. Lane , Jay A. Morrison , Steven C. Butner , Andrew Szweda
发明人： Jay E. Lane , Jay A. Morrison , Steven C. Butner , Andrew Szweda
IPC分类号： C04B35/78 , B32B5/14 , C04B35/80 , C04B35/84 , C04B35/00
CPC分类号： C04B35/185 , C04B35/803 , C04B38/0038 , C04B2111/00612 , C04B2235/3217 , C04B2235/3224 , C04B2235/3227 , C04B2235/3239 , C04B2235/3244 , C04B2235/326 , C04B2235/3287 , C04B2235/3463 , C04B2235/447 , C04B2235/522 , C04B2235/5228 , C04B2235/5256 , Y10T428/249957
摘要： A ceramic matrix composite (CMC) material (10) with increased interlaminar strength is obtained without a corresponding debit in other mechanical properties. This is achieved by infusing a diffusion barrier layer (20) into an existing porous matrix CMC to coat the exposed first matrix phase (19) and fibers (12), and then densifying the matrix with repeated infiltration cycles of a second matrix phase (22). The diffusion barrier prevents undesirable sintering between the matrix phases and between the second matrix phase and the fibers during subsequent final firing and use of the resulting component (30) in a high temperature environment.
摘要翻译：获得具有增加的层间强度的陶瓷基复合材料（CMC）材料（10），而在其它机械性能中没有相应的借方。这通过将扩散阻挡层（20）注入到现有的多孔基质CMC中以涂覆暴露的第一基质相（19）和纤维（12），然后用第二基质相（22）的重复渗透循环来致密化基质来实现）。扩散阻挡层在随后的最后焙烧和使用所得组分（30）在高温环境中，防止基质相之间和第二基质相与纤维之间的不期望的烧结。

8. 发明授权

US07745022B2 CMC with multiple matrix phases separated by diffusion barrier 有权
标题翻译：具有通过扩散阻挡层分离的多个矩阵相的CMC
公开(公告)号：US07745022B2
公开(公告)日：2010-06-29
申请号：US11489855
申请日：2006-07-20
申请人： Jay E. Lane , Jay A. Morrison , Steven C. Butner , Andrew Szweda
发明人： Jay E. Lane , Jay A. Morrison , Steven C. Butner , Andrew Szweda
IPC分类号： B32B9/00
CPC分类号： C04B35/185 , C04B35/803 , C04B38/0038 , C04B2111/00612 , C04B2235/3217 , C04B2235/3224 , C04B2235/3227 , C04B2235/3239 , C04B2235/3244 , C04B2235/326 , C04B2235/3287 , C04B2235/3463 , C04B2235/447 , C04B2235/522 , C04B2235/5228 , C04B2235/5256 , Y10T428/249957
摘要： A ceramic matrix composite (CMC) material (10) with increased interlaminar strength is obtained without a corresponding debit in other mechanical properties. This is achieved by infusing a diffusion barrier layer (20) into an existing porous matrix CMC to coat the exposed first matrix phase (19) and fibers (12), and then densifying the matrix with repeated infiltration cycles of a second matrix phase (22). The diffusion barrier prevents undesirable sintering between the matrix phases and between the second matrix phase and the fibers during subsequent final firing and use of the resulting component (30) in a high temperature environment.
摘要翻译：获得具有增加的层间强度的陶瓷基复合材料（CMC）材料（10），而在其它机械性能中没有相应的借方。这通过将扩散阻挡层（20）注入到现有的多孔基质CMC中以涂覆暴露的第一基质相（19）和纤维（12），然后用第二基质相（22）的重复渗透循环来致密化基质来实现）。扩散阻挡层在随后的最后焙烧和使用所得组分（30）在高温环境中，防止基质相之间和第二基质相与纤维之间的不期望的烧结。

9. 发明授权

US07413700B2 Methods of manufacturing insulated ceramic matrix composite 有权
标题翻译：绝缘陶瓷基复合材料的制造方法
公开(公告)号：US07413700B2
公开(公告)日：2008-08-19
申请号：US11649061
申请日：2007-01-03
申请人： Gary B. Merrill , Jay E. Lane , Steven C. Butner , Robert Kreutzer , Jay A. Morrison
发明人： Gary B. Merrill , Jay E. Lane , Steven C. Butner , Robert Kreutzer , Jay A. Morrison
IPC分类号： B28B11/04
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。

10. 发明授权

US5928775A Surface protection of porous ceramic bodies 失效
标题翻译：多孔陶瓷体的表面保护
公开(公告)号：US5928775A
公开(公告)日：1999-07-27
申请号：US878217
申请日：1997-06-17
申请人： Robert A. DiChiara, Jr. , Steven C. Butner
发明人： Robert A. DiChiara, Jr. , Steven C. Butner
IPC分类号： C04B41/50 , B32B3/26
CPC分类号： C04B41/009 , C04B41/5027 , C04B2111/00982
摘要： A surface of a porous ceramic body is protected by binding ceramic particles entirely within the subsurface porosity of the body adjacent to the surface but not present as a separately identifiable surface layer. To produce such a protective layer, a slurry of a mixture of a ceramic powder and a silica-containing binding agent is first prepared. The slurry is impregnated into the surface of the body so that all of the slurry enters the porosity of the body and substantially none of the slurry resides on the surface. The slurry is dried in place, and the residual solids are fired to bind the ceramic powder to the interior walls of the porosity. Drying and firing can be accomplished at intermediate temperatures of about 700-1000.degree. F. using heat lamps, so that the surface protection can be accomplished without removing the ceramic body from a larger structure.
摘要翻译：多孔陶瓷体的表面通过将陶瓷颗粒完全结合在与表面相邻的本体的地下孔隙中而不作为单独可识别的表面层而被保护。为了制备这样的保护层，首先制备陶瓷粉末和含二氧化硅的粘合剂的混合物的浆料。将浆料浸渍到主体的表面中，使得所有的浆料都进入到主体的孔隙中，并且基本上没有浆料驻留在表面上。将浆料干燥在适当的位置，并且将残留的固体烧制以将陶瓷粉末结合到孔隙的内壁。使用加热灯可以在约700-1000°F的中间温度下进行干燥和烧制，从而可以在不从较大结构中去除陶瓷体的情况下实现表面保护。

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