# US 2021/0079804 A1 · Cmc component with integral cooling channels and method of manufacture

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- Number: US 2021/0079804 A1
- Document ID: US20210079804A1
- Status: Published application
- Kind: A1
- Application number: 16/785,161
- Filed: 2020-02-07
- Published: 2021-03-18
- Earliest claimed: 2019-02-08
- Assignees: United Technologies Corporation
- Applicants: United Technologies Corporation
- Inventors: Thomas E. Clark; Daniel J. Whitney; Kathryn S. Read; Andrew J. Lazur; William M. Barker
- Web page: https://patentgrep.com/patent/US20210079804A1

## CPC

- F01D 5/282: {Selecting composite materials, e.g. blades with reinforcing filaments}
- F01D 11/12: using a rubstrip, e.g. erodible. deformable or resiliently-biased part
- B28B 1/002: {assembled from preformed elements}
- B32B 18/00: Layered products essentially comprising ceramics, e.g. refractory products
- C04B 35/62868: {Boron nitride}
- F01D 11/08: for sealing space between rotor blade tips and stator (specially-shaped blade tips therefor F01D5/20)
- F01D 25/12: Cooling
- C04B 2235/5224: Alumina or aluminates
- C04B 2235/5228: Silica and alumina, including aluminosilicates, e.g. mullite
- C04B 2235/524: Non-oxidic, e.g. borides, carbides, silicides or nitrides
- C04B 2235/5244: Silicon carbide
- C04B 2235/5248: Carbon, e.g. graphite
- C04B 2237/365: Silicon carbide
- C04B 2237/38: Fiber or whisker reinforced
- C04B 2237/62: Forming laminates or joined articles comprising holes, channels or other types of openings
- C04B 2237/84: Joining of a first substrate with a second substrate at least partially inside the first substrate, where the bonding area is at the inside of the first substrate, e.g. one tube inside another tube
- F05D 2230/20: essentially without removing material
- F05D 2240/11: Shroud seal segments
- F05D 2240/12: Fluid guiding means, e.g. vanes
- F05D 2260/20: Heat transfer, e.g. cooling
- F05D 2260/202: by film cooling
- F05D 2260/941: particularly aimed at mechanical or thermal stress reduction
- F05D 2300/20: Oxide or non-oxide ceramics
- F05D 2300/6033: Ceramic matrix composites [CMC]
- F05D 2300/6034: Orientation of fibres, weaving, ply angle
- Y02T 50/60: Efficient propulsion technologies, e.g. for aircraft
- F01D: NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES (machines or engines for liquids F03; non-positive displacement pumps F04D)
- B28B: SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER (foundry moulding B22C; working stone or stone-like material B28D; shaping of substances in a plastic state, in general B29C; making layered products not composed wholly of these substances B32B)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- F05D: INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION

## Abstract

A fiber-reinforced component for use in a gas turbine engine includes a first braided fiber sleeve forming a cooling channel and a plurality of fiber plies enclosing the first braided fiber sleeve, with the plurality of fiber plies forming first and second walls separated by the first braided fiber sleeve. The fiber-reinforced component further includes a matrix material between fibers of the braided fiber sleeve and the plurality of fiber plies.

## Claims

### Claim 1

A fiber-reinforced component for use in a gas turbine engine, the fiber-reinforced component comprising:
a first braided fiber sleeve forming a cooling channel;
a plurality of fiber plies enclosing the first braided fiber sleeve, the plurality of fiber plies forming first and second walls separated by the first braided fiber sleeve; and
a matrix material between fibers of the braided fiber sleeve and the plurality of fiber plies.

### Claim 2 (depends on 1)

The fiber-reinforced component of claim 1, and further comprising an aperture extending through the first wall into the cooling channel to provide cooling fluid to the cooling channel.

### Claim 3 (depends on 2)

The fiber-reinforced component of claim 2, wherein at least one of the plurality of fiber plies is formed from a second braided fiber sleeve.

### Claim 4 (depends on 3)

The fiber-reinforced component of claim 3, wherein the second braided fiber sleeve forms an outermost fiber layer of the component.

### Claim 5 (depends on 2)

The fiber-reinforced component of claim 2, wherein the component comprises a plurality of cooling channels formed from a plurality of braided fiber sleeves including the first braided fiber sleeve, wherein the plurality of braided fiber sleeves is enclosed by the plurality of fiber plies.

### Claim 6 (depends on 5)

The fiber-reinforced component of claim 5, wherein the plurality of braided fiber sleeves have a compressed shape with radiused sides separated by elongated sides forming a cooling channel with a height ranging from 0.5 to 2 millimeters (20 to 80 thousandths of an inch).

### Claim 7 (depends on 5)

The fiber-reinforced component of claim 5, wherein the plurality of braided fiber sleeves have a compressed shape with radiused sides having a radius ranging from 0.25 millimeters to 1 millimeter.

### Claim 8 (depends on 7)

The fiber-reinforced component of claim 7, wherein the component is a blade outer air seal (BOAS) and wherein the plurality of cooling channels extend in a circumferential direction relative to an engine axis.

### Claim 9 (depends on 8)

The fiber-reinforced component of claim 8, wherein the plurality of braided fiber sleeves and the plurality of fiber plies comprise materials selected from the group consisting of carbon fibers and ceramic fibers.

### Claim 10 (depends on 9)

The fiber-reinforced component of claim 9, wherein the plurality of braided fiber sleeves comprise a triaxial braid.

### Claim 11 (depends on 9)

The fiber-reinforced component of claim 9, wherein each of the plurality of braided fiber sleeves forming the plurality of cooling channels comprises nested braided fiber sleeves forming an outer diameter wall and an inner diameter wall.

### Claim 12 (depends on 1)

The fiber-reinforced component of claim 1, wherein the matrix material comprises a ceramic.

### Claim 13

A method for manufacturing a fiber-reinforced component with integral fiber-formed cooling channels for use in a gas turbine engine, the method comprising:
forming a first braided fiber sleeve;
consolidating the first braided fiber sleeve to form a cooling channel of a desired shape;
enclosing the first braided fiber sleeve with a plurality of fiber plies to form a fiber preform of a component with internal cooling provided by the cooling channel; and
densifying the fiber preform.

### Claim 14 (depends on 13)

The method of claim 13, and further comprising densifying the first braided fiber sleeve prior to enclosing the first braided fiber sleeve with a plurality of fiber plies.

### Claim 15 (depends on 13)

The method of claim 13, and further comprising:
forming the cooling channel by placing the first braided fiber sleeve on a graphite or dissolvable tooling; and
removing the tooling during or subsequent to densifying the fiber preform.

### Claim 16 (depends on 13)

The method of claim 13, and further comprising:
forming a second braided fiber sleeve;
consolidating the second braided fiber sleeve to form a second cooling channel of a desired shape;
positioning the second braided fiber sleeve adjacent to the first braided fiber sleeve; and
enclosing the second braided fiber sleeve with the plurality of fiber plies.

### Claim 17 (depends on 16)

The method of claim 16, wherein the plurality of fiber plies comprises a third braided fiber sleeve.

### Claim 18 (depends on 17)

The method of claim 17, and further comprising positioning the third braided fiber sleeve around the first and second braided fiber sleeves and positioning the third braided fiber sleeve to form an outermost fiber layer of the fiber preform.

### Claim 19 (depends on 16)

The method of claim 16, wherein the first and second fiber sleeves each comprises nested braided fiber sleeves forming an inner diameter wall and an outer diameter wall.

### Claim 20 (depends on 16)

The method of claim 16, wherein the first and second braided fiber sleeves comprise a triaxial braid.