Multi-Layer Thermal Protection System for Hypersonic Vehicles

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Solution Overview

Problem

Conventional thermal protection systems for hypersonic vehicles are heavy and bulky, increasing the weight and reducing the internal volume of the vehicle, while also failing to efficiently manage heat transfer due to their thickness.

Innovation Solution

A multi-layer thermal protection system comprising a ceramic matrix composite outboard facesheet layer, a passive insulation layer, a septum layer to separate insulation materials, and a phase change insulation layer, integrated structurally with the vehicle to minimize weight and volume while effectively managing heat transfer through radiation and phase change materials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a thick plate is used for thermal protection, then heat insulation performance is improved, but vehicle weight increases and internal volume decreases

Engineering Contradiction:

Improveheat insulation performanceVSAvoidvehicle weight

Core Design Contradiction:

TemperatureVSWeight of moving object

Solution Approach 1:

The thermal protection system is divided into multiple functional layers: an outer ceramic matrix composite layer for high-temperature protection, a middle passive insulation layer for thermal isolation, and an inner phase change material layer for active heat management. This segmentation allows each layer to be optimized for its specific function, achieving superior insulation performance with reduced overall thickness and weight compared to a single thick plate.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system employs composite material construction combining ceramic matrix composites, passive insulation materials, and phase change materials. This multi-material composite approach leverages the high-temperature resistance of ceramics, the insulating properties of passive materials, and the heat-absorbing capacity of phase change materials, creating a lightweight yet highly effective thermal protection system.

Inventive Principle:

Principle #40Composite materials

2Temperature

If a thick plate is used for thermal protection, then heat insulation performance is improved, but internal volume for other components decreases

Engineering Contradiction:

Improveheat insulation performanceVSAvoidinternal volume

Core Design Contradiction:

TemperatureVSVolume of moving object

Solution Approach 1:

By segmenting the thermal protection into multiple thin functional layers rather than one thick plate, the system achieves equivalent or superior insulation performance with significantly reduced thickness, thereby preserving internal vehicle volume for other components.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The incorporation of phase change materials provides active thermal management within a thin layer. These materials absorb and release heat during phase transitions, enhancing insulation performance without requiring increased thickness, thus maintaining internal volume availability.

Inventive Principle:

Principle #36Phase transitions

3Ease of manufacture

If conventional insulation materials are used, then manufacturing simplicity is maintained, but heat transfer management efficiency is insufficient

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidheat transfer management efficiency

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

Phase change materials are integrated into the thermal protection system to actively manage heat transfer. These materials absorb excess heat during phase transitions (e.g., melting), reducing heat transfer to the vehicle structure. This enhances energy management efficiency while maintaining a relatively simple layered manufacturing process.

Inventive Principle:

Principle #36Phase transitions

Solution Approach 2:

The composite structure combining multiple material types (ceramic matrix composites, passive insulation, phase change materials) enables sophisticated heat transfer management. Each material contributes specific thermal properties, allowing the system to optimize heat rejection, insulation, and active heat absorption without significantly complicating the manufacturing process.

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 system provides equivalent heat protection with reduced thickness, weight, and volume, enhancing vehicle performance by dissipating heat through phase change and radiation, and offering improved durability and structural integrity.

Implementation Method 1

A second layer includes a phase change insulation material

Methodology Applied

Scientific EffectPhase change: Phase Change

Implementation Method 2

dissipating heat through phase change

Methodology Applied

Scientific EffectLatent heat: Latent Heat

Implementation Method 3

A first layer includes a passive insulation material

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS9475593B2Dual layer sandwich for thermal management

Publication Date: 2016.10.25 THE BOEING CO

AI summary

A thermal protection system including a plurality of layers. A first layer includes a passive insulation material. A second layer includes a phase change insulation material. A third layer is positioned between the first layer and the second layer to separate the passive insulation material from the phase change insulation material.