Co-cured Multi-Functional Protective Assemblies for Aerospace Structures
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Solution Overview
Problem
Aerospace vehicles face challenges with existing adhesive bonding methods for protective systems, which result in weak mechanical bonds, added weight, thermal and mechanical impedance, and susceptibility to failure under environmental stresses, as well as difficulties in repair.
Innovation Solution
A protective assembly comprising multiple regions (radiation, ballistic, electrical charge, and thermal protection) formed using composite materials with specific matrix and particle configurations, and a co-curing process to create a seamless, chemically bonded interface with the aerospace structure, enhancing interfacial strength and reducing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive bonding is used to join protective systems to aerospace vehicles, then the protective system can be attached to the vehicle exterior, but the bond strength is weak and the system may break away during operation
Solution Approach 1:
The patent merges the protective system layers and the aerospace vehicle structure into a single integrated composite structure through co-curing. The adhesive and structural components are combined into one monolithic piece during the curing process, eliminating the distinct bond line and creating a unified structure that cannot separate, thereby resolving the weakness and reliability issues of traditional adhesive bonding.
Solution Approach 2:
The patent employs composite materials consisting of multiple layers including adhesive layers, protective system layers, and structural components. These composite materials are co-cured together to form an integrated structure that combines the advantages of different materials while eliminating the weaknesses of separate adhesive bonding, achieving both strength and reliability.
2Strength
If adhesive bonding is used to join protective systems, then the protective system can be attached to the vehicle, but additional weight is added to the aerospace vehicle
Solution Approach 1:
By merging the protective system and structural components into a single co-cured composite structure, the patent eliminates the need for separate adhesive layers that would add weight. The integrated structure achieves bonding strength without the additional weight penalty of discrete adhesive applications.
3Strength
If adhesive bonding is used to join protective systems, then the protective system can be attached to the vehicle exterior, but thermal and mechanical impedance are introduced at the bond line
Solution Approach 1:
The patent merges the protective system layers and structural components into a continuous integrated structure through co-curing, eliminating the distinct bond line where thermal and mechanical impedance would occur. This continuous structure allows for uniform heat flow and stress distribution without interruption from adhesive layers.
4Strength
If adhesive bonding is used to join protective systems, then the protective system can be attached to the vehicle, but the bond line is susceptible to failure by thermal and mechanical stresses
Solution Approach 1:
The patent merges all components into a single co-cured composite structure that eliminates the vulnerable bond line. The integrated structure distributes thermal and mechanical stresses uniformly throughout the entire assembly without concentration at adhesive interfaces, thereby preventing stress-related failures.
5Strength
If adhesive bonding is used to join protective systems, then the protective system can be attached to the vehicle exterior, but repair is difficult in the event of damage
Solution Approach 1:
The patent segments the protective system into distinct removable layers that can be separated from the underlying structure. This segmentation allows damaged portions to be accessed and repaired without compromising the entire structure, making repair significantly easier while maintaining strong bonding through the co-cured integration of intact portions.
Data Source
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AI summary
A protective assembly (100) comprises a first region (102) formulated and configured to provide protection from alpha, beta, and electromagnetic radiation and comprising a composite of particles and polymer; a second region (104) formulated and configured to provide protection from ballistic impact and comprising a composite of fibers and polymer; and a third region (108) formulated and configured to provide protection from thermal radiation and comprising a composite of particles, fiber, and polymer. The protective assembly may be provided on an aerospace structure (110, see Fig. 2). The protective assembly may be formed on the aerospace structure body using a co-curing process.