Heat Resistant Composite Structures with Multi-Layer Thermal Protection
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Solution Overview
Problem
Composite structures, such as those used in aircraft landing gear, are prone to losing structural integrity and igniting when exposed to heat, necessitating effective heat protection to prevent such damage.
Innovation Solution
A heat resistant system is integrated into composite structures, comprising a composite core with a thermal barrier layer made from materials like montmorillonite and polyvinyl alcohol, a heat dissipation layer with materials like boron nitride, and an intumescent layer that reacts to form char or foam to suppress heat and flames, along with a protective mesh for enhanced protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If composite structures are exposed to heat, then weight reduction and structural performance are improved, but structural integrity is lost and ignition occurs
Solution Approach 1:
The heat resistant system is divided into multiple functional layers: thermal barrier layer (montmorillonite, aluminum hydroxide) for heat reflection, heat dissipation layer (boron nitride, graphite) for thermal conduction, and intumescent layer (melamine cyanurate, polyphosphates) for flame suppression. This segmentation allows each layer to address specific aspects of heat protection while maintaining overall structural integrity.
Solution Approach 2:
The patent applies composite materials at multiple levels: the heat resistant system itself is a composite of organic binders (polyvinyl alcohol, polyacrylamide) and inorganic heat-resistant materials; the outer composite layer integrates additional heat-resistant additives into the structural composite. This multi-level composite approach provides both weight efficiency and thermal protection.
2Object-affected harmful factors
If heat resistant coatings are applied to composite structures, then protection from heat exposure is improved, but device complexity increases
Solution Approach 1:
Multiple heat protection functions are merged into a single integrated heat resistant system that can be applied as a unified coating on the composite core. The system combines thermal barrier, heat dissipation, and intumescent properties in one application process, reducing manufacturing complexity compared to applying separate coatings for each function.
Solution Approach 2:
The heat resistant system provides multiple protective functions simultaneously: thermal reflection, heat conduction away from the core, and flame suppression. This multi-functionality reduces the need for multiple separate protection systems, thereby simplifying the overall device complexity.
3Reliability
If intumescent materials are incorporated into the heat resistant system, then ignition resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The intumescent materials (melamine cyanurate, polyphosphates, pentaerythritol) are pre-incorporated into the heat resistant system coating before application to the composite core. This preliminary incorporation ensures uniform distribution and immediate functionality upon heat exposure, eliminating the need for post-application treatments or complex assembly steps.
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 system effectively prevents ignition and structural damage from heat exposure, as demonstrated by withstanding flame exposure for extended periods without igniting, showcasing its efficacy in protecting composite structures from thermal threats.
Implementation Method 1
a thermal barrier layer made from materials like montmorillonite and polyvinyl alcohol
Implementation Method 2
a heat dissipation layer with materials like boron nitride
Implementation Method 3
an intumescent layer that reacts to form char or foam to suppress heat and flames
Data Source
Figure 1
Figure 2A~2B
Figure 3A~4B
AI summary
A composite structure (300) may comprise a composite core (310) comprising a composite material, and a heat resistant system (320) coupled to the composite core comprising a binder and/or at least one of a heat dissipation material or a thermal barrier material. The heat dissipation material may comprise boron nitride, graphene, graphite, carbon fiber, carbon nanotubes, aluminum foil, and/or copper foil, and the thermal barrier material may comprise montmorillonite, aluminum hydroxide, magnesium hydroxide, silicate glass, mica powder or flake, aluminum oxide powder, titanium dioxide powder, and/or zirconium oxide powder. The binder may comprise at least one of polyvinyl alcohol, polyvinyl alcohol copolyacetate, polyacrylamide, polyethylene glycol, polyethylenimine, polyurethane, polyester, or latex.