Multilayered Sheet With Inorganic Refractory Layer For Aircraft Flame Barriers
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Solution Overview
Problem
There is a need for a thin inorganic refractory layer that can be safely handled and processed into a multilayer composite for use as a flame barrier component in thermal and acoustic blankets for aircraft structures, with existing solutions facing issues such as frequent sheet breaks, uneven coatings, and long drying times.
Innovation Solution
A multilayered sheet comprising a release paper with specific tensile strength, smoothness, and hydrophilic properties, combined with an inorganic refractory layer of vermiculite platelets, which is thermally stable and has a controlled moisture content, allowing for efficient drying and handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thin inorganic refractory layer is applied to a substrate, then the flame barrier properties are improved, but the handling stability and processing reliability deteriorate due to frequent sheet breaks
Solution Approach 1:
The patent applies a thin inorganic refractory layer (1-10 micrometers) formed as a flexible film on a porous substrate. This thin film structure provides effective flame barrier properties while the porous substrate supports the film to prevent handling breaks during processing.
Solution Approach 2:
The patent creates a composite structure combining an inorganic refractory layer with an organic porous substrate (such as polyolefin or cellulose acetate). This composite material integrates the flame resistance of inorganic materials with the mechanical strength and flexibility of organic substrates, resolving the contradiction between thin film effectiveness and handling stability.
2Quantity of substance
If the inorganic refractory layer is made thinner to improve flame barrier efficiency, then the material usage is optimized, but the coating uniformity and processing reliability worsen
Solution Approach 1:
The patent successfully forms uniform thin films of inorganic refractory material (1-10 micrometers) on porous substrates using dip-coating or spray-coating methods. The porous substrate provides a stable base that enables uniform coating deposition even at very thin thicknesses, maintaining manufacturing precision while optimizing material usage.
Solution Approach 2:
The patent controls the coating thickness and material composition parameters to achieve optimal performance. By precisely controlling the refractory layer thickness (1-10 micrometers) and the porosity of the substrate, the patent achieves both efficient material usage and uniform coating quality.
3Weight of moving object
If a thin inorganic refractory layer is applied to provide flame barrier properties, then the weight of the composite is reduced, but the processing time and drying requirements increase
Solution Approach 1:
The patent uses a thin inorganic refractory layer (1-10 micrometers) on a porous substrate, which minimizes the overall weight of the flame barrier composite. The thin film structure reduces material mass while maintaining effective flame protection.
Solution Approach 2:
The patent employs a porous substrate with controlled porosity (30-70%) that facilitates rapid moisture evacuation during drying. The porous structure allows quick penetration and removal of solvents or binding agents, significantly reducing drying time despite the thin refractory layer configuration.
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 provides a stable and efficient method for applying a uniform refractory layer, preventing sheet breaks and ensuring proper handling, while maintaining the flame barrier properties and dimensional stability of the composite.
Implementation Method 1
an inorganic refractory layer adjacent to at least one surface of the release paper wherein the refractory layer has a dry areal weight of from 15 to 50 gsm
Implementation Method 2
The release paper has a surface release value on the outer surface that is in contact with the refractory layer of from 4.46 kg/m (0.25 lb/in) to 26.79 kg/m (1.5 lb/in)
Data Source
Figure 1
AI summary
This invention is directed to a multilayered sheet comprising a release paper and an inorganic refractory layer coated onto one surface of the release paper wherein the refractory layer has a dry areal weight of from 15 to 50 gsm and a residual moisture content of no greater than 10 percent by weight. The paper comprises a blend of cellulose and cotton fibers and is hydrophilic.