Hollow-Particle Ceramic Panels for Complex High-Temperature Insulation

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Solution Overview

Problem

Conventional insulating ceramic panels are costly and heavy, limiting their applications, and are difficult to fabricate with complex, arcuate, and/or nonlinear surface profiles and internal features.

Innovation Solution

Insulating ceramic panels composed of hollow particles and an oxide binder, formed through binder jet printing and solvent-infusion, allowing for the attachment of hollow particles and fusion into a lightweight, durable structure with complex shapes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional insulating ceramic panels are used, then structural strength and heat resistance are achieved, but cost and weight increase

Engineering Contradiction:

Improvestructural strengthVSAvoidpanel weight

Core Design Contradiction:

StrengthVSWeight of stationary object

Solution Approach 1:

The patent employs hollow particles with controlled wall thickness (3-30% of equivalent particle diameter) to create a porous microstructure within the ceramic panel. These hollow particles serve as both structural reinforcement and thermal insulation, reducing overall panel weight while maintaining strength and heat resistance properties

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The invention creates a composite structure combining hollow particles (metal oxide material) with oxide binder material. This composite approach allows the panel to achieve both mechanical strength from the particle framework and thermal insulation from the controlled porosity, while reducing weight compared to solid conventional ceramics

Inventive Principle:

Principle #40Composite materials

2Strength

If conventional insulating ceramic panels are used, then structural integrity is maintained, but manufacturing complexity increases for complex shapes

Engineering Contradiction:

Improvestructural integrityVSAvoidfabrication ease

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent utilizes binder jet printing technology to deposit hollow particles and binder material in controlled layers, then infuses oxide binder material into interstitial spaces. This parameter-controlled manufacturing process enables complex arcuate and nonlinear surface profiles to be formed directly during fabrication while maintaining structural integrity through controlled particle bonding

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention replaces traditional mechanical forming and assembly processes with a digital printing and infusion method. The binder jet printing system deposits particles according to digital models, and the oxide binder material is infused through capillary action into interstitial spaces, eliminating the need for complex mechanical tooling and assembly operations required by conventional methods

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The method results in cost-effective, lightweight ceramic panels with enhanced strength and durability, capable of forming complex shapes, suitable for high-temperature environments.

Implementation Method 1

an oxide binder material that attaches each hollow particle to at least one other hollow particle

Methodology Applied

Scientific EffectChemical bonding: Chemical Bonding

Implementation Method 2

heating the solution-infused panel. The heating includes evaporating a solvent

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 3

degrading the binder jet binder material

Methodology Applied

Scientific EffectThermal decomposition: Pyrolysis

Implementation Method 4

fusing the plurality of hollow particles to one another to define the insulating ceramic panel

Methodology Applied

Scientific EffectSintering: Sintering

Data Source

PatentUS12509403B2Insulating ceramic panels and methods of forming insulating ceramic panels

Publication Date: 2025.12.30 THE BOEING CO

AI summary

Insulating ceramic panels and methods of forming insulating ceramic panels are disclosed herein. The insulating ceramic panels include a plurality of hollow particles and an oxide binder. The plurality of hollow particles are formed from a hollow particle material that includes a metal oxide. The plurality of hollow particles defines an average equivalent particle diameter of at least 10 micrometers (μm) and at most 500 μm. In addition, the plurality of hollow particles defines an average wall thickness that is at least 3% and at most 30% of the average equivalent particle diameter. The oxide binder material attaches each hollow particle to at least one other hollow particle and differs from the hollow particle material. The insulating ceramic panels define a particle-enclosed void volume fraction, which is enclosed within the plurality of hollow particles, and an interstitial void volume fraction, which is defined within an interstitial space among the plurality of hollow particles.