US6418973B1
Expired / Lapsed
US
⏱️ 0.0 years remaining
Integrally woven ceramic composites
Assignee: Boeing Co
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Filing: 1998-12-23
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Granted: 2002-07-16
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Expires: 2018-12-23
Abstract
Abstract A woven preform for a ceramic composite has a plurality of layers and structural members. The plurality of layer are of woven yarns of fibrous material. The structural members extend between the layers. The layers and members define interlayer spaces. One or more of the layers may have a plurality of openings extending therethrough. Low density ceramic insulation made be deposited in the interlayer spaces via a slurry that enters the preform, or the preform after it has been made a part of a composite, through the openings. The carrier of the slurry exits the preform, leaving the randomly packed fibers in the interlayer spaces. The structural members may be walls that, along with the layers, define channels. The channels may be used to direct fluid through so as the composite functions as an insulator. The channels may be directed in the warp direction for achieving increased benefits.
Inventors
- 👤 Brian N. Cox
- 👤 David B. Marshall
- 👤 Janet B. Davis
- 👤 Min Z. Berbon
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-05 21:36
CPC Classifications
B; B32; B32B; B32B5/00; B32B5/22; B32B5/24; B32B5/26; B32B3/00; B32B3/10; B32B3/18; B32B3/20; B32B5/02; B32B5/024; B32B5/06; C; C04; C04B; C04B35/00; C04B35/01; C04B35/14; C04B35/16; C04B35/18; C04B35/185; C04B35/447; C04B35/515; C04B35/56; C04B35/565; C04B35/571; C04B35/58; C04B35/584; C04B35/589; C04B35/622; C04B35/626; C04B35/628; C04B35/62844; C04B35/62857; C04B35/62873; C04B35/62881; C04B35/62897; C04B35/71; C04B35/78; C04B35/80; C04B35/83; D; D03; D03D; D03D11/00; D03D11/02; D03D25/00; D03D25/005; F; F02; F02K; F02K1/00; F02K1/78; F02K1/82; F02K1/822; F02K9/00; F02K9/42; F02K9/60; F02K9/62; F02K9/64; F02K9/97; F02K9/972; F23; F23M; F23M5/00; B32B2307/00; B32B2307/30; B32B2307/304; C04B2235/00; C04B2235/02; C04B2235/30; C04B2235/32; C04B2235/3217; C04B2235/3224; C04B2235/3225; C04B2235/3227; C04B2235/38; C04B2235/3817; C04B2235/3826; C04B2235/40; C04B2235/402; C04B2235/46; C04B2235/465; C04B2235/48; C04B2235/483; C04B2235/50; C04B2235/52; C04B2235/5208; C04B2235/5216; C04B2235/522; C04B2235/5224; C04B2235/524; C04B2235/5244; C04B2235/5248; C04B2235/5252; C04B2235/5256; C04B2235/70; C04B2235/80; D10; D10B; D10B2403/00; D10B2403/02; D10B2403/021; D10B2505/00; D10B2505/02; F05; F05D; F05D2300/00; F05D2300/20; F05D2300/21; F05D2300/60; F05D2300/603; F23M2900/00; F23M2900/05004
Claims Analysis
Total Claims: 51
Claim 1
Independent Claim
67 words
A woven preform for a ceramic composite comprising: plurality of layers of woven yarns of fibrous material; structural members extending between the layers; the layers and the structural members defining interlayer spaces; low density ceramic insulation being disposed in the interlayer spaces; and a plurality of openings extending through at least one of the layers, wherein said openings are large enough for the insulation to pass through.
Claim 2
Dependent Claim
67 words
A woven preform for a ceramic composite comprising: plurality of layers of woven yarns of fibrous material; structural members extending between the layers; the layers and the structural members defining interlayer spaces; low density ceramic insulation being disposed in the interlayer spaces; and a plurality of openings extending through at least one of the layers, wherein said openings are large enough for the insulation to pass through.
Claim 3
Dependent Claim
26 words
The woven preform of claim 1 , wherein the low density ceramic insulation comprises fibers having a length shorter than an average width of the openings.
Claim 4
Dependent Claim
35 words
The woven preform of claim 1 , wherein the plurality of layers of woven yarns comprise: an upper layer; a lower layer; and one or more central layers disposed between the upper and lower layers.
Claim 5
Dependent Claim
22 words
The woven preform of claim 3 , wherein at least a portion of the plurality of openings extend through the upper layer.
Claim 6
Dependent Claim
26 words
The woven preform of claim 3 , wherein at least a portion of the plurality of openings extend through at least one of the central layers.
Claim 7
Dependent Claim
34 words
The woven preform of claim 3 , wherein low density ceramic insulation is disposed in the interlayer spaces, the insulation comprising of fibers having a length shorter than an average width of the openings.
Claim 8
Dependent Claim
18 words
The woven preform of claim 6 , wherein the opening average width is approximately 2 mm or greater.
Claim 9
Dependent Claim
32 words
The woven preform of claim 6 , wherein the low density ceramic insulation comprises Al 2 O 3 fibers or SiO 2 fibers that are randomly distributed in a three dimensional arrangement.
Claim 10
Dependent Claim
23 words
The woven preform of claim 1 , wherein the interlayer spaces are channels that are defined by the layers and the structural members.
Claim 11
Dependent Claim
15 words
The woven preform of claim 9 , wherein the channels extend in a warp direction.
Claim 12
Dependent Claim
17 words
The woven preform of claim 9 , wherein low density ceramic insulation is disposed in the channels.
Claim 13
Dependent Claim
18 words
The woven preform of claim 1 , wherein a ceramic composite comprises the woven preform and a matrix.
Claim 14
Dependent Claim
41 words
A woven preform for a ceramic composite, the preform comprising: at least three spaced layers of woven yarns of fibrous material; and walls extending between the layers; wherein the layers and the walls define channels that extend in a warp direction.
Claim 15
Dependent Claim
41 words
A woven preform for a ceramic composite, the preform comprising: at least three spaced layers of woven yarns of fibrous material; and walls extending between the layers; wherein the layers and the walls define channels that extend in a warp direction.
Claim 16
Dependent Claim
30 words
The woven preform of claim 13 , further comprising: low density ceramic insulation that is disposed in the channels; and a plurality of openings extending through one of the layers.
Claim 17
Dependent Claim
18 words
The woven preform of claim 10 , wherein the channels are further defined by circumferentially woven weft fibers.
Claim 18
Dependent Claim
13 words
The woven preform of claim 15 , wherein the channels are generally cylindrical.
Claim 19
Dependent Claim
18 words
The woven preform of claim 10 , wherein a ceramic composite comprises the woven preform and a matrix.
Claim 20
Dependent Claim
18 words
The woven preform of claim 15 , wherein a ceramic composite comprises the woven preform and a matrix.
Claim 21
Dependent Claim
18 words
The woven preform of clai 15 , wherein a ceramic composite comprises the woven preform and a matrix.
Claim 22
Dependent Claim
18 words
The woven preform of clai 15 , wherein a ceramic composite comprises the woven preform and a matrix.
Claim 23
Dependent Claim
18 words
The woven preform of claim 16 , wherein a ceramic composite comprises the woven preform and a matrix.
Claim 24
Dependent Claim
18 words
The woven preform of claim 13 , wherein the channels are further defined by circumferentially woven weft fibers.
Claim 25
Dependent Claim
13 words
The woven preform of claim 21 , wherein the channels are generally cylindrical.
Claim 26
Dependent Claim
17 words
The woven preform of claim 14 , wherein the channels are defined by circumferentially woven weft fibers.
Claim 27
Dependent Claim
13 words
The woven preform of claim 23 , wherein the channels are generally cylindrical.
Claim 28
Dependent Claim
29 words
A process for weaving a ceramic preform comprising the step of weaving warp channels that are defined by three spaced layers with structural members extending between the three layers.
Claim 29
Dependent Claim
29 words
A process for weaving a ceramic preform comprising the step of weaving warp channels that are defined by three spaced layers with structural members extending between the three layers.
Claim 30
Dependent Claim
33 words
The process of claim 25 , wherein the weaving the warp channels step further comprises the step of weaving the warp channels such that weft fibers are circumferentially disposed about the warp channels.
Claim 31
Dependent Claim
11 words
A ceramic preform made by the process of claim 26 .
Claim 32
Dependent Claim
12 words
The process of claim 27 , wherein the channels are generally cylindrical.
Claim 33
Dependent Claim
11 words
A ceramic preform made by the process of claim 28 .
Claim 34
Dependent Claim
26 words
The process of claim 26 , further comprising the step of weaving a terminus end from an end of at least one of the warp channels.
Claim 35
Dependent Claim
11 words
A ceramic preform made by the process of claim 30 .
Claim 36
Dependent Claim
27 words
The process of claim 26 , further comprising the step of weaving a curved terminus extending from an end of at least one of the warp channels.
Claim 37
Dependent Claim
11 words
A ceramic preform made by the process of claim 32 .
Claim 38
Dependent Claim
44 words
The process of claim 32 , wherein the weaving the curved terminus step comprises the step of inserting additional weft fibers into a side of the curved terminus such that the curved terminus side is longer than an opposing curved terminus side after beating.
Claim 39
Dependent Claim
31 words
The process of claim 34 , wherein the weaving the curved terminus step further comprises the step of not weaving the additional weft fibers in to the opposing curved terminus side.
Claim 40
Dependent Claim
47 words
The process of claim 32 , wherein the weaving the curved terminus step comprises the step of not weaving all of the weft fibers into a side of the curved terminus such that the curved terminus side is shorter than an opposing curved terminus side after beating.
Claim 41
Dependent Claim
91 words
A process for weaving a ceramic preform comprising the steps of: a) weaving warp channels that are defined by two layers with structural members extending between the two layers, wherein weft fibers are circumferentially disposed about the warp channels; and b) weaving a curved terminus extending from an end of at least one of the warp channels, wherein step b) includes a step of inserting additional weft fibers into a side of the curved terminus such that the curved terminus side is longer than an opposing curved terminus side after beating.
Claim 42
Dependent Claim
91 words
A process for weaving a ceramic preform comprising the steps of: a) weaving warp channels that are defined by two layers with structural members extending between the two layers, wherein weft fibers are circumferentially disposed about the warp channels; and b) weaving a curved terminus extending from an end of at least one of the warp channels, wherein step b) includes a step of inserting additional weft fibers into a side of the curved terminus such that the curved terminus side is longer than an opposing curved terminus side after beating.
Claim 43
Dependent Claim
30 words
The process of claim 37 , wherein the weaving the curved terminus step further comprises the step of not weaving the additional weft fibers into the opposing curved terminus side.
Claim 44
Dependent Claim
95 words
A process for weaving a ceramic preform comprising the steps of: a) weaving warp channels that are defined by two layers with structural members extending between the two layers, wherein weft fibers are circumferentially disposed about the warp channels; and b) weaving a curved terminus extending from an end of at least one of the warp channels, wherein step b) further comprises the step of not weaving all of the weft fibers into a side of the curved terminus such that the curved terminus side is shorter than an opposing curved terminus side after beating.
Claim 45
Dependent Claim
95 words
A process for weaving a ceramic preform comprising the steps of: a) weaving warp channels that are defined by two layers with structural members extending between the two layers, wherein weft fibers are circumferentially disposed about the warp channels; and b) weaving a curved terminus extending from an end of at least one of the warp channels, wherein step b) further comprises the step of not weaving all of the weft fibers into a side of the curved terminus such that the curved terminus side is shorter than an opposing curved terminus side after beating.
Claim 46
Dependent Claim
85 words
A woven preform for a ceramic composite, the preform comprising: at least two layers of woven yarns of fibrous material; walls extending between the layers, said walls being disposed substantially orthogonally to each of said two layers; the layers and the walls defining substantially rectangular channels that extend in a warp direction; low density ceramic insulation that is disposed in the channels; and a plurality of openings extending through one of the layers, wherein said openings are large enough for the insulation to pass through.
Claim 47
Dependent Claim
85 words
A woven preform for a ceramic composite, the preform comprising: at least two layers of woven yarns of fibrous material; walls extending between the layers, said walls being disposed substantially orthogonally to each of said two layers; the layers and the walls defining substantially rectangular channels that extend in a warp direction; low density ceramic insulation that is disposed in the channels; and a plurality of openings extending through one of the layers, wherein said openings are large enough for the insulation to pass through.
Claim 48
Dependent Claim
65 words
A woven preform for a ceramic composite, the preform comprising: at least two layers of woven yarns of fibrous material; substantially cylindrical channels that extend in a warp direction between said layers; low density ceramic insulation than is disposed in the channels; and a plurality of openings extending through one of the layers, wherein said openings are large enough for the insulation to pass through.
Claim 49
Dependent Claim
65 words
A woven preform for a ceramic composite, the preform comprising: at least two layers of woven yarns of fibrous material; substantially cylindrical channels that extend in a warp direction between said layers; low density ceramic insulation than is disposed in the channels; and a plurality of openings extending through one of the layers, wherein said openings are large enough for the insulation to pass through.
Claim 50
Dependent Claim
69 words
A woven preform for a ceramic composite, the preform comprising: at least two layers of woven yarns of fibrous material; walls extending between the layers, the layers and the walls defining channels that extend in a warp direction; low density ceramic insulation disposed in said channels; and a plurality of openings extending through one of the layers, wherein said openings are large enough for the insulation to pass through.
Claim 51
Dependent Claim
69 words
A woven preform for a ceramic composite, the preform comprising: at least two layers of woven yarns of fibrous material; walls extending between the layers, the layers and the walls defining channels that extend in a warp direction; low density ceramic insulation disposed in said channels; and a plurality of openings extending through one of the layers, wherein said openings are large enough for the insulation to pass through.
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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) | 2005-07-15 | 2006-01-14 | 2006-07-16 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2009-07-15 | 2010-01-14 | 2010-07-16 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2013-07-15 | 2014-01-14 | 2014-07-16 | $7700.00 | Window Closed / Lapsed |