Composite Part Thermal Barrier via Resin Injection
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Solution Overview
Problem
Existing thermal protection solutions for organic matrix composite material parts in aeroengines are costly and weight-penetrating, requiring additional parts or coatings that are difficult to fasten and increase the overall weight of the components.
Innovation Solution
A method involving an injection mold process to integrate a thermal protection barrier by injecting and hardening a resin layer with a lower thermal diffusion coefficient than the composite material, eliminating the need for external parts and minimizing weight increase, using either identical or different thermosetting and thermoplastic resins with controlled glass transition or melting temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If additional parts or coatings such as thermal blankets or metal screens are used for thermal protection, then thermal protection is provided, but the overall weight of the part significantly increases
Solution Approach 1:
The invention merges the thermal protection function with the structural core by integrating insulation material directly into the composite material structure during fabrication. This eliminates separate thermal protection parts and reduces overall weight while maintaining protective functionality.
Solution Approach 2:
The invention uses composite materials comprising fiber reinforcement and matrix material, where the matrix material serves dual purposes as both structural binder and thermal insulation layer. This composite approach provides thermal protection without the weight penalty of traditional metal or separate insulation components.
2Object-affected harmful factors
If additional parts or coatings such as thermal blankets or metal screens are used for thermal protection, then thermal protection is provided, but the cost of fabrication increases
Solution Approach 1:
The invention combines thermal protection with the structural core fabrication process, eliminating the need for separate assembly steps and reducing overall manufacturing cost. The insulation material is applied during the same fabrication cycle as the structural composite, reducing labor and assembly costs.
Solution Approach 2:
The structural core itself provides thermal protection through its composite structure, eliminating the need for additional protective coatings or separate thermal protection components. The matrix material inherently provides insulation, making the structure self-protecting.
3Object-affected harmful factors
If additional parts or coatings such as thermal blankets or metal screens are used for thermal protection, then thermal protection is provided, but fastening becomes difficult and requires specific fastener means
Solution Approach 1:
The invention integrates the thermal protection layer with the structural core through direct bonding during fabrication, eliminating the need for separate fastening mechanisms. The insulation material is applied and cured as part of the same process, creating a monolithic structure without requiring bolts, inserts, or Velcro.
4Weight of moving object
If fiber reinforcement is densified with organic matrix, then weight is reduced, but the composite material cannot withstand temperatures higher than acceptable limits
Solution Approach 1:
The invention uses a composite structure with fiber reinforcement and matrix material where the matrix provides thermal insulation properties. This allows the lightweight composite structure to also withstand high temperatures by leveraging the insulating characteristics of the organic matrix material.
Solution Approach 2:
The invention applies thermal insulation specifically at the surface layer of the composite structure, where thermal exposure occurs. The fiber reinforcement provides structural strength while the matrix material provides thermal protection, creating local functional differentiation within the composite.
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 provides effective thermal protection without increasing the part's weight or cost, as the resin layer acts as a poor heat conductor, fully integrated into the structural core fabrication, reducing thermal diffusion and maintaining mechanical strength.
Implementation Method 1
The resin layer presents a thermal diffusion coefficient that is much less than that of the fiber structure, acting as a poor conductor of heat and providing thermal protection
Implementation Method 2
injecting a first resin into the first chamber; solidifying the resin injected into the first chamber
Data Source
AI summary
A method of making a structural part having a thermal protection barrier is provided. The method includes: making a fiber structure; introducing the fiber structure into an injection mold having first and second chambers, the fiber structure being placed in the second chamber; placing a movable separator partition between the first and second chambers; injecting a first resin into the first chamber; solidifying the resin injected into the first chamber; withdrawing the movable separator partition; injecting a second resin into the second chamber containing the fiber texture; and hardening the resins present in the first and second chambers of the injection mold in such a manner as to obtain a part having a structural core made of composite material constituted by fiber reinforcement densified by an organic matrix, and a thermal barrier constituted by a layer of hardened resin.