Ceramic Matrix Composite Thermal Insulation for Impact Resistance

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Solution Overview

Problem

Current high-temperature ceramic thermal insulation tiles used in extreme environments, such as space vehicles, are delicate, prone to impact damage, and require frequent replacement due to heat-induced shrinking or debris damage, and lack durability and larger, seamless surfaces that can withstand temperatures above 1204°C (2200°F).

Innovation Solution

A thermal insulation assembly comprising a ceramic tile with a mullite-alumina ceramic matrix composite (CMC) facesheet and an interface layer, which provides enhanced durability, impact resistance, and heat resistance, along with an optional emissivity coating to increase surface emissivity, allowing the assembly to maintain structural integrity and smoothness at extreme temperatures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional ceramic tiles are used for thermal insulation, then they provide basic thermal protection, but they are delicate and susceptible to impact damage requiring frequent replacement

Engineering Contradiction:

ImprovedurabilityVSAvoidimpact damage susceptibility

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies composite materials by combining ceramic fiber insulation with a mullite-alumina ceramic matrix composite facesheet. The ceramic matrix composite provides enhanced mechanical strength and impact resistance while maintaining thermal insulation properties, thereby resolving the contradiction between basic thermal protection and durability against impact damage.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the material parameters by transitioning from traditional ceramic tiles to a ceramic matrix composite structure with specific composition (mullite-alumina). This parameter change results in improved mechanical properties and resistance to impact damage while maintaining thermal insulation performance.

Inventive Principle:

Principle #35Parameter changes

2Temperature

If ceramic tiles are used in high temperature environments, then they provide thermal insulation, but they shrink from high heat requiring frequent replacement

Engineering Contradiction:

Improveheat resistanceVSAvoidthermal stability

Core Design Contradiction:

TemperatureVSStability of the object's composition

Solution Approach 1:

The patent uses a ceramic matrix composite structure where the mullite-alumina matrix provides high-temperature structural stability. This composite material maintains its dimensional stability and prevents shrinking at temperatures above 1204°C, resolving the contradiction between providing thermal insulation and maintaining compositional stability under high heat.

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If smaller ceramic tiles are used, then they are easier to manufacture, but they create more gaps and joints reducing insulation effectiveness

Engineering Contradiction:

Improvemanufacturing easeVSAvoidinsulation coverage area

Core Design Contradiction:

Ease of manufactureVSArea of stationary object

Solution Approach 1:

The patent changes the manufacturing parameters by implementing a larger tile format with the ceramic matrix composite structure. This parameter change allows for fewer gaps and joints while maintaining manufacturability through the standardized fabrication process, thereby increasing the effective insulation coverage area.

Inventive Principle:

Principle #35Parameter changes

4Temperature

If ceramic tiles are used to protect against heat, then they provide thermal protection, but they have rough surfaces that render chemical species at high temperatures

Engineering Contradiction:

Improvethermal protectionVSAvoidsurface smoothness

Core Design Contradiction:

TemperatureVSShape

Solution Approach 1:

The patent applies a ceramic matrix composite facesheet with controlled surface morphology. The mullite-alumina matrix provides a smoother surface finish compared to traditional ceramic tiles, reducing the rendering of chemical species at high temperatures while maintaining thermal protection capabilities.

Inventive Principle:

Principle #40Composite materials

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 solution results in a thermal insulation assembly with improved durability, resistance to impact and heat, and a seamless surface that can withstand temperatures exceeding 2200°F without embrittlement, reducing the need for frequent replacements and offering cost-effective fabrication methods.

Implementation Method 1

A thermal insulation assembly comprises a ceramic tile with a mullite-alumina ceramic matrix composite (CMC) facesheet and an interface layer, which provides enhanced durability, impact resistance, and heat resistance

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 2

an optional emissivity coating to increase surface emissivity, allowing the assembly to maintain structural integrity and smoothness at extreme temperatures

Methodology Applied

Scientific EffectEmissivity: Thermal Radiation

Data Source

PatentEP2109537B1Thermal insulation assemblies and methods for fabricating the same

Publication Date: 2018.03.28 THE BOEING CO

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AI summary

Thermal insulation assemblies and methods for fabricating thermal insulation assemblies are provided. In an exemplary embodiment, a thermal insulation assembly comprises a ceramic tile having a surface coated with an alumina-mullite slurry. A ceramic matrix composite is disposed on the coated surface. The ceramic matrix composite comprises a first ply of a ceramic fiber impregnated with a ceramic matrix.