US6238617B1
Expired / Lapsed
US
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Method for forming a ceramic matrix composite turbocharger housing
Assignee: Northrop Grumman Corp
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Filing: 1999-09-27
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Granted: 2001-05-29
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Expires: 2019-09-27
Abstract
Abstract A heat-resistant, thermally insulative, ductile turbocharger housing for an internal combustion engine having a structure comprised at least partially of fiber reinforced ceramic matrix composite (FRCMC) material. The FRCMC material includes a polymer-derived ceramic resin in its ceramic form and fibers. The material, being for the most part ceramic, provides the heat-resistance and thermal insulating capabilities of the FRCMC material, while the fibers produce a desired degree of ductility in the FRCMC material.
Inventors
- 👤 Thomas Edward Strasser
- 👤 Steven Donald Atmur
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-05 20:23
CPC Classifications
F; F02; F02B; F02B39/00; C; C04; C04B; C04B35/00; C04B35/01; C04B35/16; C04B35/18; C04B35/515; C04B35/56; C04B35/565; C04B35/571; C04B35/622; C04B35/626; C04B35/628; C04B35/62844; C04B35/62857; C04B35/6286; C04B35/62863; C04B35/62865; C04B35/62868; C04B35/62871; C04B35/62873; C04B35/71; C04B35/78; C04B35/80; F01; F01D; F01D25/00; F01D25/24; F02B37/00; C04B2235/00; C04B2235/02; C04B2235/30; C04B2235/32; C04B2235/3217; C04B2235/34; C04B2235/3418; C04B2235/38; C04B2235/3817; C04B2235/3826; C04B2235/3852; C04B2235/3873; C04B2235/50; C04B2235/52; C04B2235/5208; C04B2235/5212; C04B2235/5216; C04B2235/522; C04B2235/5224; C04B2235/5228; C04B2235/524; C04B2235/5244; C04B2235/5248; C04B2235/5252; F05; F05D; F05D2220/00; F05D2220/40; Y; Y02; Y02T; Y02T10/00; Y02T10/10; Y02T10/12; Y10; Y10T; Y10T428/00; Y10T428/13; Y10T428/131; Y10T428/249921; Y10T428/249924; Y10T428/249928; Y10T428/249931
Claims Analysis
Total Claims: 12
Claim 1
Independent Claim
161 words
A method for forming a heat-resistant, thermally insulative, ductile turbocharger housing having a shaped interior surface, comprising the steps of: (a) forming a fiber preform in a shape of the turbocharger housing from continuous woven fibers; (b) inserting a mandrel having the shape of the interior surface of the turbocharger housing into the preform; (c) placing the preform in a cavity of a mold having a shape of the turbocharger housing; (d) forcing a liquid pre-ceramic polymer resin through the cavity to fill the cavity and saturate the preform; (e) heating the mold for a time and at a temperature sufficient to transform the preform saturated with the liquid pre-ceramic polymer resin to a polymer composite turbocharger housing; (f) removing the polymer composite turbocharger housing from the mold; (g) removing the mandrel; and (h) firing the polymer composite turbocharger housing in an inert atmosphere for a time and at a temperature sufficient to transform the pre-ceramic polymer resin to a ceramic.
Claim 2
Independent Claim
161 words
A method for forming a heat-resistant, thermally insulative, ductile turbocharger housing having a shaped interior surface, comprising the steps of: (a) forming a fiber preform in a shape of the turbocharger housing from continuous woven fibers; (b) inserting a mandrel having the shape of the interior surface of the turbocharger housing into the preform; (c) placing the preform in a cavity of a mold having a shape of the turbocharger housing; (d) forcing a liquid pre-ceramic polymer resin through the cavity to fill the cavity and saturate the preform; (e) heating the mold for a time and at a temperature sufficient to transform the preform saturated with the liquid pre-ceramic polymer resin to a polymer composite turbocharger housing; (f) removing the polymer composite turbocharger housing from the mold; (g) removing the mandrel; and (h) firing the polymer composite turbocharger housing in an inert atmosphere for a time and at a temperature sufficient to transform the pre-ceramic polymer resin to a ceramic.
Claim 3
Dependent Claim
96 words
The method of claim 1 , further comprising the steps of, after step (h) thereof: (i) immersing the turbocharger housing containing pores formed by outgassing during firing into a bath of the liquid pre-ceramic polymer resin to fill the pores with the liquid pre-ceramic polymer resin; (j) firing the turbocharger housing in an inert atmosphere for a time and at a temperature sufficient to transform the pre-ceramic polymer resin in the pores to a ceramic; and (k) repeating steps (i) and (j) until the pore density within the turbocharger housing is less than a preestablished percentage.
Claim 4
Dependent Claim
23 words
The method of claim 1 , wherein the mandrel comprises a melt-out material and the step of removing the mandrel comprises melting it.
Claim 5
Dependent Claim
23 words
The method of claim 1 , wherein the mandrel comprises a wash-out material and the step of removing the mandrel comprises dissolved it.
Claim 6
Independent Claim
157 words
A method for forming a heat-resistant, thermally insulative, ductile turbocharger housing having a shaped interior surface and a shaped exterior, comprising the steps of: (a) placing a mandrel having the shape of the interior surface of the turbocharger housing into a cavity of a mold, said cavity having a shape of the exterior of the turbocharger housing; (b) injecting a quantity of bulk molding compound into the cavity of the mold, said cavity having walls which form the turbocharger housing, and said bulk molding compound comprising a pre-ceramic resin and fibers; (c) heating the mold at a temperature and for a time associated with the pre-ceramic resin which polymerizes the resin to form a fiber-reinforced polymer composite turbocharger housing; (d) removing the polymerized composite turbocharger housing from the mold; (e) removing the mandrel; and (f) heating the polymerized composite turbocharger housing for a temperature and for a time associated with the polymerized resin which pyrolizes the resin.
Claim 7
Independent Claim
157 words
A method for forming a heat-resistant, thermally insulative, ductile turbocharger housing having a shaped interior surface and a shaped exterior, comprising the steps of: (a) placing a mandrel having the shape of the interior surface of the turbocharger housing into a cavity of a mold, said cavity having a shape of the exterior of the turbocharger housing; (b) injecting a quantity of bulk molding compound into the cavity of the mold, said cavity having walls which form the turbocharger housing, and said bulk molding compound comprising a pre-ceramic resin and fibers; (c) heating the mold at a temperature and for a time associated with the pre-ceramic resin which polymerizes the resin to form a fiber-reinforced polymer composite turbocharger housing; (d) removing the polymerized composite turbocharger housing from the mold; (e) removing the mandrel; and (f) heating the polymerized composite turbocharger housing for a temperature and for a time associated with the polymerized resin which pyrolizes the resin.
Claim 8
Dependent Claim
86 words
The method of claim 5 , further comprising the steps of, after step (f) thereof: (g) immersing the turbocharger housing containing pores formed during the firing into a bath of pre-ceramic resin to fill the pores; (h) heating the turbocharger housing at a temperature and for a time associated with the resin filling said pores so as to transform it to a ceramic material; (i) repeating steps (g) and (h) until the pore density within the turbocharger housing is less than a prescribed percentage by volume.
Claim 9
Dependent Claim
23 words
The method of claim 5 , wherein the mandrel comprises a melt-out material and the step of removing the mandrel comprises melting it.
Claim 10
Dependent Claim
23 words
The method of claim 5 , wherein the mandrel comprises a wash-out material and the step of removing the mandrel comprises dissolved it.
Claim 11
Independent Claim
122 words
A method of forming a turbocharger housing component, comprising the steps of: a) choosing a polymer-derived ceramic resin from a silicon-carboxyl resin, or alumina silicate resin; b) choosing fibers comprising at least one of alumina, silicon nitride, silicon carbide, graphite carbon, and peat; c) coating said fibers with an interface material comprising at least one 0.1-0.5 micron thick layer of at least one of carbon, silicon nitride, silicon carbide, and boron nitride; d) choosing a filler material comprising at least one of alumina, silica, silicon carbide, and silicon nitride; e) combining said filler material, coated fibers and resin; f) forming the turbocharger housing component from the combined filler material, coated fibers and resin; and g) curing the resin to form a ceramic.
Claim 12
Independent Claim
122 words
A method of forming a turbocharger housing component, comprising the steps of: a) choosing a polymer-derived ceramic resin from a silicon-carboxyl resin, or alumina silicate resin; b) choosing fibers comprising at least one of alumina, silicon nitride, silicon carbide, graphite carbon, and peat; c) coating said fibers with an interface material comprising at least one 0.1-0.5 micron thick layer of at least one of carbon, silicon nitride, silicon carbide, and boron nitride; d) choosing a filler material comprising at least one of alumina, silica, silicon carbide, and silicon nitride; e) combining said filler material, coated fibers and resin; f) forming the turbocharger housing component from the combined filler material, coated fibers and resin; and g) curing the resin to form a ceramic.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 2004-05-28 | 2004-11-27 | 2005-05-29 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2008-05-28 | 2008-11-27 | 2009-05-29 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2012-05-28 | 2012-11-27 | 2013-05-29 | $7700.00 | Window Closed / Lapsed |