Patents by Inventor Steven C. Butner
Steven C. Butner has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 7745022Abstract: A ceramic matrix composite (CMC) material (10) with increased interlaminar strength is obtained without a corresponding debit in other mechanical properties. This is achieved by infusing a diffusion barrier layer (20) into an existing porous matrix CMC to coat the exposed first matrix phase (19) and fibers (12), and then densifying the matrix with repeated infiltration cycles of a second matrix phase (22). The diffusion barrier prevents undesirable sintering between the matrix phases and between the second matrix phase and the fibers during subsequent final firing and use of the resulting component (30) in a high temperature environment.Type: GrantFiled: July 20, 2006Date of Patent: June 29, 2010Assignee: Siemens Energy, Inc.Inventors: Jay E. Lane, Jay A. Morrison, Steven C. Butner, Andrew Szweda
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Publication number: 20100119807Abstract: A ceramic matrix composite (CMC) material (10) with increased interlaminar strength is obtained without a corresponding debit in other mechanical properties. This is achieved by infusing a diffusion barrier layer (20) into an existing porous matrix CMC to coat the exposed first matrix phase (19) and fibers (12), and then densifying the matrix with repeated infiltration cycles of a second matrix phase (22). The diffusion barrier prevents undesirable sintering between the matrix phases and between the second matrix phase and the fibers during subsequent final firing and use of the resulting component (30) in a high temperature environment.Type: ApplicationFiled: July 20, 2006Publication date: May 13, 2010Inventors: Jay E. Lane, Jay A. Morrison, Steven C. Butner, Andrew Szweda
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Patent number: 7413700Abstract: A composite material (10) formed of a ceramic matrix composite (CMC) material (12) protected by a ceramic insulating material (14). The constituent parts of the insulating material are selected to avoid degradation of the CMC material when the two layers are co-processed. The CMC material is processed to a predetermined state of shrinkage before wet insulating material is applied against the CMC material. The two materials are then co-fired together, with the relative amount of shrinkage between the two materials during the firing step being affected by the amount of pre-shrinkage of the CMC material during the bisque firing step. The shrinkage of the two materials during the co-firing step may be matched to minimize shrinkage stresses, or a predetermined amount of prestress between the materials may be achieved. An aluminum hydroxyl chloride binder material (24) may be used in the insulating material in order to avoid degradation of the fabric (28) of the CMC material during the co-firing step.Type: GrantFiled: January 3, 2007Date of Patent: August 19, 2008Assignee: Siemens Power Generation, Inc.Inventors: Gary B. Merrill, Jay E. Lane, Steven C. Butner, Robert Kreutzer, Jay A. Morrison
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Patent number: 7179524Abstract: A composite material (10) formed of a ceramic matrix composite (CMC) material (12) protected by a ceramic insulating material (14). The constituent parts of the insulating material are selected to avoid degradation of the CMC material when the two layers are co-processed. The CMC material is processed to a predetermined state of shrinkage before wet insulating material is applied against the CMC material. The two materials are then co-fired together, with the relative amount of shrinkage between the two materials during the firing step being affected by the amount of pre-shrinkage of the CMC material during the bisque firing step. The shrinkage of the two materials during the co-firing step may be matched to minimize shrinkage stresses, or a predetermined amount of prestress between the materials may be achieved. An aluminum hydroxyl chloride binder material (24) may be used in the insulating material in order to avoid degradation of the fabric (28) of the CMC material during the co-firing step.Type: GrantFiled: September 19, 2003Date of Patent: February 20, 2007Assignee: Siemens Power Generation, Inc.Inventors: Gary B. Merrill, Jay E. Lane, Steven C. Butner, Robert Kreutzer, Jay A. Morrison
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Patent number: 7093359Abstract: A method of manufacturing a composite structure uses a layer of an insulating material (22) as a mold for forming a substrate of a ceramic matrix composite (CMC) material (24). The insulating material may be formed in the shape of a cylinder (10) with the CMC material wound on an outer surface (14) of the cylinder to form a gas turbine combustor liner (20). Alternatively, the insulating material may be formed in the shape of an airfoil section (32) with the CMC material formed on an inside surface (36) of the insulating material. The airfoil section may be formed of a plurality of halves (42, 44) to facilitate the lay-up of the CMC material onto an easily accessible surface, with the halves then joined together to form the complete composite airfoil. In another embodiment, a box structure (102) defining a hot gas flow passage (98) is manufactured by forming insulating material in the shape of opposed airfoil halves (104) joined at respective opposed ends by platform members (109).Type: GrantFiled: September 17, 2002Date of Patent: August 22, 2006Assignee: Siemens Westinghouse Power CorporationInventors: Jay A. Morrison, Gary Brian Merrill, Jay Edgar Lane, Steven C. Butner, Harry A. Albrecht, Scott M. Widrig, Yevgeniy P. Shteyman
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Publication number: 20050076504Abstract: A method of manufacturing a composite structure uses a layer of an insulating material (22) as a mold for forming a substrate of a ceramic matrix composite (CMC) material (24). The insulating material may be formed in the shape of a cylinder (10) with the CMC material wound on an outer surface (14) of the cylinder to form a gas turbine combustor liner (20). Alternatively, the insulating material may be formed in the shape of an airfoil section (32) with the CMC material formed on an inside surface (36) of the insulating material. The airfoil section may be formed of a plurality of halves (42, 44) to facilitate the lay-up of the CMC material onto an easily accessible surface, with the halves then joined together to form the complete composite airfoil. In another embodiment, a box structure (102) defining a hot gas flow passage (98) is manufactured by forming insulating material in the shape of opposed airfoil halves (104) joined at respective opposed ends by platform members (109).Type: ApplicationFiled: September 17, 2002Publication date: April 14, 2005Inventors: Jay A. Morrison, Gary Merrill, Jay Edgar Lane, Steven C. Butner, Harry A. Albrecht, Scott Widrig, Yevgeniy Shteyman
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Patent number: 6746755Abstract: A multi-layer ceramic matrix composite structure (40) having a plurality of fiber-reinforced cooling passages (42) formed therein. The cooling passages are formed by the removal of a fugitive material (24). The fugitive material is part of a wrapped fugitive material structure (28) containing a layer of reinforcing ceramic fibers (26) that is used to lay-up the multi-layer structure. An intermediate layer of ceramic fabric 56 may be placed alternately over and under the wrapped fugitive material structure to separate the cooling passages into alternating upper (54) and lower (52) cooling passages. The transversely oriented fibers surrounding the cooling passages serve to increase the interlaminar strength of the structure when compared to prior art designs. An airfoil member (112) incorporating such reinforced integral cooling passages (120) is provided.Type: GrantFiled: September 24, 2001Date of Patent: June 8, 2004Assignee: Siemens Westinghouse Power CorporationInventors: Jay Morrison, Steven C. Butner, Christian X. Campbell, Harry A. Albrecht, Yevgeuiy Shteyman
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Publication number: 20040058201Abstract: A composite material (10) formed of a ceramic matrix composite (CMC) material (12) protected by a ceramic insulating material (14). The constituent parts of the insulating material are selected to avoid degradation of the CMC material when the two layers are co-processed. The CMC material is processed to a predetermined state of shrinkage before wet insulating material is applied against the CMC material. The two materials are then co-fired together, with the relative amount of shrinkage between the two materials during the firing step being affected by the amount of pre-shrinkage of the CMC material during the bisque firing step. The shrinkage of the two materials during the co-firing step may be matched to minimize shrinkage stresses, or a predetermined amount of prestress between the materials may be achieved. An aluminum hydroxyl chloride binder material (24) may be used in the insulating material in order to avoid degradation of the fabric (28) of the CMC material during the co-firing step.Type: ApplicationFiled: September 19, 2003Publication date: March 25, 2004Applicant: Siemens Westinghouse Power CorporationInventors: Gary B. Merrill, Jay E. Lane, Steven C. Butner, Robert Kreutzer, Jay A. Morrison
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Patent number: 6648597Abstract: A ceramic matrix composite material (CMC) vane for a gas turbine engine wherein the airfoil member (12) and the platform member (14) are formed separately and are then bonded together to form an integral vane component (10). Airfoil member and the platform member may be bonded together by an adhesive (20) after being fully cured. Alternatively, respective joint surfaces (16, 18) of the green body state airfoil member and platform member may be co-fired together to form a sinter bond (30). A mechanical fastener (38) and/or a CMC doubler (42) may be utilized to reinforce the bonded joint (40). A matrix infiltration process (50) may be used to create or to further strengthen the bond.Type: GrantFiled: May 31, 2002Date of Patent: November 18, 2003Assignee: Siemens Westinghouse Power CorporationInventors: Scott M. Widrig, Jay Morrison, Harry A. Albrecht, Yevgeniy Shteyman, Steven C. Butner
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Publication number: 20030059577Abstract: A multi-layer ceramic matrix composite structure (40) having a plurality of fiber-reinforced cooling passages (42) formed therein. The cooling passages are formed by the removal of a fugitive material (24). The fugitive material is part of a wrapped fugitive material structure (28) containing a layer of reinforcing ceramic fibers (26) that is used to lay-up the multi-layer structure. An intermediate layer of ceramic fabric 56 may be placed alternately over and under the wrapped fugitive material structure to separate the cooling passages into alternating upper (54) and lower (52) cooling passages. The transversely oriented fibers surrounding the cooling passages serve to increase the interlaminar strength of the structure when compared to prior art designs. An airfoil member (112) incorporating such reinforced integral cooling passages (120) is provided.Type: ApplicationFiled: September 24, 2001Publication date: March 27, 2003Applicant: Siemens Westinghouse Power CorporationInventors: Jay Morrison, Steven C. Butner, Christian X. Campbell, Harry A. Albrecht, Yevgeuiy Shteyman
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Patent number: 5928775Abstract: A surface of a porous ceramic body is protected by binding ceramic particles entirely within the subsurface porosity of the body adjacent to the surface but not present as a separately identifiable surface layer. To produce such a protective layer, a slurry of a mixture of a ceramic powder and a silica-containing binding agent is first prepared. The slurry is impregnated into the surface of the body so that all of the slurry enters the porosity of the body and substantially none of the slurry resides on the surface. The slurry is dried in place, and the residual solids are fired to bind the ceramic powder to the interior walls of the porosity. Drying and firing can be accomplished at intermediate temperatures of about 700-1000.degree. F. using heat lamps, so that the surface protection can be accomplished without removing the ceramic body from a larger structure.Type: GrantFiled: June 17, 1997Date of Patent: July 27, 1999Assignee: McDonnell Douglas CorporationInventors: Robert A. DiChiara, Jr., Steven C. Butner
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Patent number: 5702761Abstract: A surface of a porous ceramic body is protected by binding ceramic particles entirely within the subsurface porosity of the body adjacent to the surface but not present as a separately identifiable surface layer. To produce such a protective layer, a slurry of a mixture of a ceramic powder and a silica-containing binding agent is first prepared. The slurry is impregnated into the surface of the body so that all of the slurry enters the porosity of the body and substantially none of the slurry resides on the surface. The slurry is dried in place, and the residual solids are fired to bind the ceramic powder to the interior walls of the porosity. Drying and firing can be accomplished at intermediate temperatures of about 700.degree.-1000.degree. F. using heat lamps, so that the surface protection can be accomplished without removing the ceramic body from a larger structure.Type: GrantFiled: April 29, 1994Date of Patent: December 30, 1997Assignee: McDonnell Douglas CorporationInventors: Robert A. DiChiara, Jr., Steven C. Butner