US 12,077,479 B2
Recession resistant intermediate layer for CMC vane
David J. Thomas, Brownsburg, IN (US); Thomas Nixon, Brownsburg, IN (US); Michael Whittle, Derby (GB); and Jeffrey Crutchfield, Long Beach, CA (US)
Assigned to Rolls-Royce Corporation, Indianapolis, IN (US); and Rolls-Royce plc, London (GB)
Filed by Rolls-Royce Corporation, Indianapolis, IN (US); and Rolls-Royce plc, London (GB)
Filed on Feb. 12, 2020, as Appl. No. 16/788,917.
Prior Publication US 2021/0246081 A1, Aug. 12, 2021
Int. Cl. C04B 41/45 (2006.01); C04B 41/50 (2006.01); C04B 41/52 (2006.01); C04B 41/87 (2006.01); B32B 3/08 (2006.01); B32B 5/06 (2006.01); B32B 18/00 (2006.01)
CPC C04B 41/4584 (2013.01) [C04B 41/4505 (2013.01); C04B 41/5024 (2013.01); C04B 41/5059 (2013.01); C04B 41/5066 (2013.01); C04B 41/52 (2013.01); C04B 41/87 (2013.01); B32B 3/08 (2013.01); B32B 5/06 (2013.01); B32B 18/00 (2013.01); B32B 2260/021 (2013.01); B32B 2262/105 (2013.01); B32B 2305/026 (2013.01); B32B 2305/80 (2013.01); B32B 2603/00 (2013.01); C04B 2235/5252 (2013.01); C04B 2235/6025 (2013.01); C04B 2235/6027 (2013.01); C04B 2235/614 (2013.01); C04B 2235/616 (2013.01); C04B 2235/96 (2013.01)] 12 Claims
OG exemplary drawing
 
1. A method of manufacturing a ceramic matrix composite (CMC) component, the method comprising:
providing at least a portion of a ceramic fiber preform comprising a lay-up of ceramic fiber plies;
embedding an environmental protection layer precursor in at least the portion of the ceramic fiber preform;
adding an isolation barrier layer to the environmental protection layer precursor;
completing the ceramic fiber preform if only the portion of the ceramic fiber preform is provided when the environmental protection layer precursor is embedded; and
forming, from the ceramic fiber preform in which the environmental protection layer precursor was embedded, a CMC body of the CMC component, wherein the CMC body comprises a CMC material completely surrounding an environmental protection layer formed from the environmental protection layer precursor,
wherein the isolation barrier layer is added to the environmental protection layer precursor before forming the CMC body, and
wherein adding the isolation barrier layer to the environmental protection layer comprises: positioning a sheet comprising ceramic particles in a binder or a preceramic polymer onto the environmental protection layer precursor; and drying and sintering the sheet together with the ceramic fiber preform.