Metal-Encapsulated Ceramic Tiles for Reusable Rocket Heat Shields

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Solution Overview

Problem

Conventional ceramic tiles used for thermal insulation in rocket engine nozzles are brittle, porous, and require frequent refurbishment and waterproofing, leading to increased weight and maintenance costs for reusable launch vehicles.

Innovation Solution

A thermal protection apparatus comprising a rigid ceramic tile sandwiched between two metal layers, secured with pins, which provides insulation while the metal layers enhance durability and prevent water ingress, reducing heat penetration and damage from foreign objects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If conventional ceramic tiles are used for thermal insulation, then insulation performance is achieved, but the tiles are brittle and require frequent refurbishment

Engineering Contradiction:

Improvethermal insulation performanceVSAvoiddurability and refurbishment frequency

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The patent combines ceramic insulation tiles with metal reinforcement layers to create a composite thermal protection system. The metal layers provide structural strength and durability while the ceramic core maintains thermal insulation performance, resolving the contradiction between insulation effectiveness and structural reliability.

Inventive Principle:

Principle #40Composite materials

2Temperature

If conventional porous ceramic tiles are used, then insulation performance is achieved, but the tiles must be waterproofed before every launch to prevent water absorption

Engineering Contradiction:

Improvethermal insulation performanceVSAvoidwaterproofing maintenance requirements

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The metal layers in the composite structure serve as impermeable barriers that prevent water from reaching the porous ceramic core. This eliminates the need for repeated waterproofing operations while preserving the insulating properties of the ceramic material.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The metal layers act as protective shells that encapsulate the ceramic insulation, providing a water-tight barrier that prevents water ingress without compromising the thermal insulation performance of the underlying ceramic structure.

Inventive Principle:

Principle #30Flexible shells and thin films

3Temperature

If conventional ceramic tiles are used, then insulation performance is achieved, but the tiles increase booster weight due to water absorption

Engineering Contradiction:

Improvethermal insulation performanceVSAvoidbooster weight

Core Design Contradiction:

TemperatureVSWeight of moving object

Solution Approach 1:

The metal encapsulation layers create a sealed structure that prevents water absorption by the ceramic core. This maintains the lightweight characteristics of the insulation system across multiple launches by preventing water uptake that would otherwise increase mass.

Inventive Principle:

Principle #40Composite materials

4Temperature

If conventional ceramic tiles are used, then insulation performance is achieved, but the tiles are not robust and require refurbishment between launches

Engineering Contradiction:

Improvethermal insulation performanceVSAvoidrobustness and damage resistance

Core Design Contradiction:

TemperatureVSStrength

Solution Approach 1:

The metal reinforcement layers provide structural strength and damage resistance to the ceramic insulation tiles. This composite construction protects the brittle ceramic from impact damage and mechanical stress during launch and landing, eliminating the need for refurbishment while maintaining thermal insulation performance.

Inventive Principle:

Principle #40Composite materials

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 solution effectively insulates rocket components from high temperatures, reduces weight by minimizing water absorption, and increases the durability of the insulation system, allowing for multiple launches with reduced refurbishment needs.

Implementation Method 1

the rigid insulation can inhibit or prevent heat from penetrating through the thermal protection apparatus to the body of the rocket during reentry

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 2

the metal layers can protect the insulation from damage

Methodology Applied

Scientific EffectMechanical protection:

Data Source

PatentUS11667408B2Metal encapsulated ceramic tile thermal insulation, and associated systems and methods

Publication Date: 2023.06.06 BLUE ORIGIN MANUFACTURING LLC

AI summary

A metal encapsulated ceramic tile thermal insulation system for rockets and associated methods is disclosed. A representative system includes a launch vehicle having a first end and a second end generally opposite the first end and includes a heat shield positioned at the second end. The heat shield includes a plurality of thermal protection apparatuses, where individual of the thermal protection apparatuses include ceramic tiles encapsulated by inner and outer metal layers, which are positioned on opposing top and bottom surfaces of the ceramic tiles. The plurality of thermal protection apparatuses includes a plurality of pins positioned within corresponding holes drilled through the ceramic tiles and are secured to the metal layers. The outer metal layer can protect the ceramic tile from tool strikes and debris and can also prevent water from reaching and being absorbed by the ceramic tile.