Cork-Based Thermal Protection Material for Aerospace
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Solution Overview
Problem
Current thermal protection materials used in the space sector are dense and heavy, limiting their mass performance and efficiency in low thermal flux applications, such as protecting launchers and re-entry vehicles, where they are subjected to short periods of high thermal stress.
Innovation Solution
A lightweight thermal protection material is developed using a high mass percentage of cork combined with refractory short carbon fibers and a binder, specifically phenolic or epoxy resin, to reduce density and enhance ablative behavior, maintaining insulating power and structural integrity under thermal stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional thermal protection materials are used, then thermal insulation is provided, but the materials are dense and heavy, limiting mass performance
Solution Approach 1:
The invention uses a composite material system combining cork particles (5-50 mesh size), phenolic resin binder, and glass ecospheres. This composite structure provides both thermal insulation and reduced density, achieving density between 0.20-0.40 g/cm³ while maintaining thermal protection capability for low flux applications up to 0.3 MW/m²
Solution Approach 2:
The material formulation incorporates glass ecospheres and cork particles to create a porous structure that reduces overall density while maintaining thermal insulation properties. The porous composition allows the material to achieve low density (0.20-0.40 g/cm³) without sacrificing thermal protection performance
2Weight of moving object
If material composition is optimized for low density, then mass performance improves, but structural integrity under thermal stress may be compromised
Solution Approach 1:
The composite formulation combines cork particles, phenolic resin, and glass ecospheres in specific proportions to achieve both low density (0.20-0.40 g/cm³) and adequate structural integrity. The phenolic resin binder provides binding strength while the glass ecospheres contribute to structural framework, enabling the material to withstand thermal stress during atmospheric re-entry
Solution Approach 2:
The invention optimizes specific parameters including cork particle mesh size (5-50), phenolic resin content (15-30 parts by weight per 100 parts cork), and glass ecosphere inclusion to achieve the optimal balance between low density and structural integrity under thermal stress conditions
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 new material achieves a significant reduction in density while maintaining thermal insulation and structural integrity, resulting in a temperature increase of over 40°C less on the protected surface compared to existing materials, thus optimizing mass performance and payload capacity.
Implementation Method 1
a binder resistant to high temperatures allow its use in the aerospace and military industries
Implementation Method 2
The natural thermal insulation capabilities of cork combined with a binder resistant to high temperatures
Implementation Method 3
This last so-called ablative behavior is fundamental for this type of materials because it allows the incoming heat flow to be reduced
Data Source
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AI summary
The subject of the invention is a thermal protection material for a surface, which material is made from a mixture comprising a resin, granules of cork and refractory fibres, characterized in that the proportion of granules of cork in the mixture corresponds to a mass percentage of 50 to 80%.