Composite Insulation Laminate for Lightweight Flame-Resistant Blankets
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Solution Overview
Problem
There is a need for thermal and acoustic blankets for aircraft structures that have reduced weight and improved flame spread resistance, as existing solutions do not adequately address the requirements for both properties simultaneously.
Innovation Solution
A composite laminate comprising a polymeric moisture barrier, an inorganic platelet layer, and a thermoplastic film layer, where each layer has a specific thickness and UL 94 flame classification of V-0, is used to create a thermal insulation and acoustic blanket. The laminate includes a polymeric moisture barrier with a thickness of 6.0 to 25.0 micrometers, an inorganic platelet layer with an aspect ratio of 100 to 20,000, and a thermoplastic film layer with a thickness no greater than 10 micrometers, which contacts and encapsulates an inorganic or organic core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing thermal and acoustic blanket materials are used, then adequate thermal insulation is provided, but weight is excessive and flame spread resistance is insufficient
Solution Approach 1:
The patent applies composite materials by combining three distinct layers with complementary properties: a polymeric moisture barrier layer (6-25 micrometers) for moisture protection, an inorganic platelet layer (7-76 micrometers) for enhanced flame resistance and thermal insulation, and a thermoplastic film layer (≤10 micrometers) for structural integrity. This multi-material composite structure achieves superior flame spread resistance and reduced weight compared to conventional single-material blankets.
Solution Approach 2:
The patent segments the blanket into three functional layers, each with specific thickness ranges and properties. The segmentation allows each layer to perform its specialized function: the polymeric layer blocks moisture, the inorganic platelet layer provides flame resistance, and the thermoplastic layer maintains structural integrity. This segmentation enables optimized weight and performance compared to homogeneous materials.
2Reliability
If existing thermal and acoustic blanket materials are used, then adequate thermal insulation is provided, but burnthrough resistance is insufficient
Solution Approach 1:
The composite laminate structure combines materials with different thermal and mechanical properties to achieve superior burnthrough resistance. The inorganic platelet layer provides high-temperature stability and flame barrier properties, while the thin overall structure (total thickness 23-111 micrometers) minimizes weight. The synergistic interaction between layers creates a lightweight but highly resistant structure against burnthrough.
Solution Approach 2:
The patent applies local quality by concentrating flame-resistant inorganic platelets in a specific layer dedicated to thermal protection, rather than distributing materials uniformly. The inorganic platelet layer is specifically engineered with 7-76 micrometer thickness to provide localized burnthrough resistance where thermal exposure occurs, while other layers optimize for moisture barrier and structural functions.
3Reliability
If thicker materials are used to improve flame resistance, then flame spread resistance improves, but weight increases
Solution Approach 1:
The patent uses composite materials to achieve high flame spread resistance with minimal weight. The inorganic platelet layer (7-76 micrometers) provides exceptional flame barrier properties due to the high-temperature stability of inorganic materials, while the overall thin structure (23-111 micrometers total) keeps weight low. This composite approach delivers superior flame protection without the weight penalty of thicker single-material constructions.
Solution Approach 2:
The patent changes material parameters by selecting specific thickness ranges for each layer: the inorganic platelet layer at 7-76 micrometers provides optimal flame resistance, the polymeric layer at 6-25 micrometers provides moisture protection, and the thermoplastic layer at ≤10 micrometers provides structural integrity. These parameter optimizations achieve maximum flame spread resistance with minimum weight.
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 laminate provides superior burnthrough resistance and weight reduction while meeting stringent flame and acoustic standards, outperforming existing materials in burnthrough tests and maintaining structural integrity and flame resistance.
Implementation Method 1
an inorganic platelet layer having a thickness from 7.0 to 76.0 micrometers and a UL 94 flame classification of V-0 wherein the platelets comprising the platelet layer have an aspect ratio of from 100 to 20,000
Implementation Method 2
thermal insulation and acoustic blanket comprising an inorganic or organic core surrounded by the above composite laminate
Implementation Method 3
a thermoplastic film layer having a thickness no greater than 10 micrometers, an average elongation to break no greater than 150% and a UL 94 flame classification of V-0
Implementation Method 4
a polymeric moisture barrier having a thickness from 6.0 to 25.0 micrometers and a UL 94 flame classification of V-0
Data Source
Figure 1~3
AI summary
This invention is directed to a composite laminate comprising in order (a) a flame retardant polymeric moisture barrier (b) an inorganic platelet layer and (c) a flame retardant thermoplastic film layer The invention is also directed to a thermal insulation and acoustic blanket comprising a core of fibrous material or foam surrounded by the above composite laminate wherein the thermoplastic film layer of the composite laminate contacts and encapsulates the core.