Ceramic Fiber Stitching for High-Temp Insulation Attachment

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

High-temperature silicone adhesives are difficult to apply on curved insulation panels, not easily removable, and have a limited operating temperature of about 550° F., restricting the thermal protection capabilities of attached insulating structures in high-temperature environments.

Innovation Solution

A non-adhesive mechanical attachment method using ceramic fibers to stitch a micro-truss structure to a substructure through open channels and holes, with a thin ceramic insulation layer for strain relief and a moldable ceramic skin for load distribution, allowing for secure attachment without adhesives and operating beyond 2200° F.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If high-temperature silicone adhesive is used to attach insulation panels, then ease of applicability and strain-relief during thermal cycling are improved, but the maximum operating temperature is limited to about 550° F. and removal difficulty increases

Engineering Contradiction:

Improveease of applicabilityVSAvoidmaximum operating temperature

Core Design Contradiction:

Ease of operationVSTemperature

Solution Approach 1:

The patent replaces the chemical adhesive bonding system with a mechanical stitching system using ceramic fibers and fasteners. This substitution eliminates the temperature limitation of adhesives (550° F.) while maintaining secure attachment capability, allowing the insulation structure to operate at temperatures up to 2200° F. or higher without degrading the attachment method.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention changes the fundamental attachment parameter from chemical bonding (adhesive) to mechanical bonding (stitching/fastening). This parameter change enables the system to withstand extreme temperatures that would degrade adhesive properties, while the modular mechanical attachment allows for easier removal and replacement of insulation panels compared to cured adhesive bonds.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If high-temperature silicone adhesive is used to attach insulation panels, then strain-relief during thermal cycling is improved, but removal difficulty increases when replacing deformed or chipped panels

Engineering Contradiction:

Improvestrain-relief during thermal cyclingVSAvoidease of removal

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The patent segments the attachment system into discrete mechanical components (fasteners, ceramic fiber stitching, attachment points) rather than a continuous adhesive bond. This segmentation allows individual insulation panels to be removed and replaced by simply unfastening the mechanical connectors, making repair significantly easier while still providing strain-relief through the flexible ceramic fiber stitching that accommodates thermal expansion and contraction.

Inventive Principle:

Principle #1Segmentation

3Temperature

If mechanical attachment with ceramic fibers is used, then operating temperature capability is improved to beyond 2200° F., but attachment complexity increases compared to adhesive methods

Engineering Contradiction:

Improveoperating temperature capabilityVSAvoidattachment complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent employs composite materials including ceramic fibers, high-temperature resistant stitching materials, and specialized fasteners that can withstand extreme temperatures. This composite attachment system integrates multiple materials with complementary properties to achieve temperature capability beyond 2200° F. while managing the complexity through material selection rather than overly complex mechanical designs.

Inventive Principle:

Principle #40Composite materials

4Ease of manufacture

If adhesive attachment is used, then ease of applicability is improved, but adaptability to curved insulation panels deteriorates

Engineering Contradiction:

Improveease of applicabilityVSAvoidadaptability to curved panels

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The patent utilizes flexible ceramic fiber stitching and thin-film-like attachment methods that can conform to curved surfaces. The ceramic fibers and stitching materials are sufficiently flexible to adapt to various panel geometries including curved surfaces, while maintaining their high-temperature structural integrity. This provides adaptability to curved panels that rigid mechanical fasteners alone could not achieve.

Inventive Principle:

Principle #30Flexible shells and thin films

Data Source

PatentUS8586179B1Mechanical attachment for micro-truss actively cooled structural insulation layer

Publication Date: 2013.11.19 THE BOEING CO

AI summary

A high temperature structural insulation layer is disclosed. A micro-truss structure comprises a porous lattice structure, and a protected substructure comprises at least one hole. At least one fiber non-adhesively couples the micro-truss structure to the protected substructure via the at least one fiber passing through one or more spaces within the porous lattice structure.