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1. WO2020112076 - REINFORCED CERAMIC MATRIX COMPOSITE COMPONENTS

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[ EN ]

CLAIMS

What we claim is:

1. A component (30) comprising an airfoil (32), the airfoil (32) comprising fiber material (62) hosted with a ceramic matrix (63), the fiber material (62) woven in successive layers about spanwise extending reinforcement members (55) to define the airfoil (32).

2. The component (30) of claim 1 , wherein the reinforcement members (55) comprise a solid material.

3. The component (30) of claim 2, wherein the solid material comprises a ceramic or a ceramic matrix composite material.

4. The component (30) of claim 1 , wherein the reinforcement members (55) comprise a body (74) having a bore (76) extending therethrough in a spanwise direction of the airfoil (32), wherein the bore (76) defines a cooling channel (78) for the

component (30).

5. The component (30) of claim 4, wherein the body (74) of the

reinforcement members (55) comprises a member selected from the group consisting of a ceramic, ceramic matrix composite material, a carbon material, and combinations thereof.

6. The component (30) of claim 1 , wherein the reinforcement members (55) comprise at least one of a braided ceramic rope or a hollow braided ceramic rope having a bore (76) extending in a spanwise direction therethrough.

7. The component (30) of claim 1 , wherein the fiber material (62) comprises a member selected from the group consisting of unidirectional fibers, fiber bundles, and a braided fiber material.

8. The component (30) of claim 1 , wherein a density of the reinforcement members (55) is greater at a trailing edge of the airfoil (32) relative to a remaining portion of the airfoil (32).

9. The component (30) of claim 1 , wherein at least a portion of the fiber material (62) extends from one of a suction side (44) to a pressure side (40) to the other of the suction side (44) and the pressure side (40) of the airfoil (32).

10. The component (30) of claim 1 , wherein the airfoil (32) comprises a rib

(82) defining a cavity (84) between a perimeter (90) of the airfoil (32) and the rib (82), wherein the rib (82) comprises at least a portion of the reinforcement members (55), and wherein the fiber material (62) extends from one of a pressure side (44) or a suction side (44) to the other of the pressure side (40) and the suction side (44) of the airfoil (32) through the rib (82).

1 1 . The component (30) of claims 1 to 10, wherein the fiber material (62) is woven about the reinforcement members (55) continuously from the root (58) to the tip (60) of the airfoil (32).

12. A method (100) of forming a component having an airfoil (32) comprising a body (34) of a ceramic matrix composite material (65), the body (34) defined between a leading edge (54) and a trailing edge (56), and between a concave portion (38) defining a pressure side (40) and a convex portion (42) defining a suction side (44), the pressure side (40) and the suction side (44) extending between the leading edge (54) and the trailing edge (56), the method (100) comprising:

positioning (102) a plurality of spanwise extending reinforcement members to define a general outline of a shape of the airfoil (32);

weaving (104) a fiber material (62) about the spanwise extending reinforcement members (55) in an axial direction (68) of the airfoil (32) and in successive layers to define the body (34) of the airfoil (32), wherein the fiber material (62) comprising an amount of a ceramic material (63) effective to produce the ceramic matrix composite material (65) upon sintering of the fiber material (62) and the ceramic material (63); and sintering (112) the fiber material (62) with ceramic material (63) woven about the reinforcement members (55) at a temperature and for a duration effective to produce the ceramic matrix composite material (65) and form the body (34) of the airfoil (32).

13. The method (100) of claim 12, wherein the fiber material (62) is pre impregnated with the ceramic material (63) prior to the weaving (104).

14. The method (100) of claim 12, wherein the reinforcement members (55) comprise a body (74) having a bore (76) extending in a spanwise direction

therethrough, wherein the bore (76) defines a cooling channel (78) for the component (30).

15. The method (100) of claim 12, wherein the weaving (104) comprises extending at least a portion of the fiber material (62) from one of the suction side (44) and the pressure side (40) to the other of the suction side (44) and the pressure side (40) of the airfoil (32).

16. The method (100) of claim 16, wherein the weaving comprises extending the fiber material over selected reinforcement members in a first pass and under the selected reinforcement members in a second pass.

17. The method claim 12, wherein a density of the reinforcement members (55) is greater at a trailing edge (56) of the airfoil than a remaining portion of the airfoil (32).

18. The method of claim 12, further comprising staggering individual layers of the fiber material (62) such that a first layer of the fiber material (62) travels over different reinforcement members (55) relative to a second layer of the fiber material (62), the second layer disposed above or below the first layer in a spanwise direction of the airfoil (32).

19. The method of claim 12, further comprising:

defining a rib (82) in the body (34) of the airfoil (32) and a cavity (84) between an outer perimeter (90) of the airfoil (32) and the rib (82); and

extending at least a portion of the fiber material (62) from the pressure side (40) to the suction side (44) of the airfoil (32) through the rib (82).

20. The method (100) of claims 12 to 19, wherein the fiber material (62) is woven about the reinforcement members (55) continuously from the root (58) to the tip (60) of the airfoil (32).