Composite Thermal Protection Structure with Porous Ceramic Insulation
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Solution Overview
Problem
Aerospace vehicles face extreme temperature and pressure conditions during high-velocity travel, necessitating effective thermal protection systems that can withstand and insulate against high temperatures while maintaining structural integrity.
Innovation Solution
A composite thermal protection structure comprising a base layer, insulating layer, and erosion-resistant layer, each with specific materials and properties, is designed to provide thermal insulation and mechanical strength, reducing stress and load requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a thermal protection structure uses dense ceramic materials to withstand high temperatures, then temperature resistance is improved, but weight increases
Solution Approach 1:
The patent employs a porous ceramic foam material as the insulating layer that provides thermal protection while maintaining low weight. The porous structure reduces material density while preserving thermal insulation properties, directly resolving the contradiction between temperature resistance and weight.
Solution Approach 2:
The patent uses a composite structure consisting of a ceramic matrix composite base layer, a porous ceramic foam insulating layer, and a ceramic coating erosion resistant layer. This multi-material composite approach optimizes both thermal protection and weight characteristics by combining materials with complementary properties.
2Temperature
If a thermal protection structure uses thick insulation layers to protect against high temperatures, then temperature protection is improved, but structural complexity increases
Solution Approach 1:
The thermal protection structure is segmented into three distinct functional layers: a ceramic matrix composite base layer for structural support, a porous ceramic foam insulating layer for thermal insulation, and a ceramic coating erosion resistant layer for surface protection. This segmentation allows each layer to be optimized for its specific function while simplifying the overall design and manufacturing process.
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 composite structure effectively protects aerospace vehicles from temperatures up to 2500°C and velocities up to Mach 8, maintaining structural integrity and reducing material and labor costs for high-volume production.
Implementation Method 1
A thermal protection structure is on the body and comprises a base layer, an insulating layer on the base layer, and an erosion resistant layer on the insulating layer
Implementation Method 2
The insulating layer exhibits a specific gravity of from about 0.01 to about 1.0 and the insulating layer comprises a ceramic foam
Implementation Method 3
an erosion resistant layer on the insulating layer
Data Source
AI summary
A composite article comprises a body comprising a radial region, a tapered region, and a cavity region. The cavity region comprises a cylindrical shape and an inner diameter of the cylindrical shape decreases between the radial region and the tapered region. A nosecone region is adjacent to the tapered region of the body and at an opposing end of the body to the cavity region. A thermal protection structure is on the body and comprises a base layer, an insulating layer is on the base layer, and an erosion resistant layer is on the insulating layer. The insulating layer exhibits a specific gravity of from about 0.01 to about 1.0. Methods of forming the thermal protection structure and of thermally protecting an article are also disclosed.