Porous Ceramic Cooling Panel for High-Temperature Thermal Stress

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Solution Overview

Problem

High-temperature components in aerospace and other vehicles face challenges with weight, deformation, and thermal stress due to the use of heavy heat-resistant materials like INCONEL, which also reflect radar and have low emissivity, making it difficult to manage heat effectively while maintaining structural integrity.

Innovation Solution

A transpirational cooling panel comprising a porous ceramic matrix composite layer, a porous high-temperature fabric layer, and machined ceramic fiber batting with ceramic stitching, allowing for thermal expansion without distorting the surface and providing efficient cooling through a porous structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If heavy heat-resistant materials like INCONEL are used, then high-temperature resistance is improved, but weight increases

Engineering Contradiction:

Improvehigh-temperature resistanceVSAvoidcomponent weight

Core Design Contradiction:

TemperatureVSWeight of moving object

Solution Approach 1:

The patent employs a composite structure combining ceramic matrix composite (CMC) material with a metallic substrate. The CMC layer provides high-temperature resistance while the metallic substrate provides structural support, achieving thermal protection with reduced weight compared to full INCONEL construction

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The CMC layer is designed with a porous structure that enables transpirational cooling - coolant flows through the pores to absorb heat internally. This porous architecture reduces material density and weight while maintaining thermal protection capabilities through active cooling

Inventive Principle:

Principle #31Porous materials

2Temperature

If heavy heat-resistant materials like INCONEL are used, then high-temperature resistance is improved, but deformation under thermal stress worsens

Engineering Contradiction:

Improvehigh-temperature resistanceVSAvoidstructural stability under thermal stress

Core Design Contradiction:

TemperatureVSStability of the object's composition

Solution Approach 1:

The composite CMC-metal structure combines materials with complementary thermal properties. The CMC layer has low thermal expansion and high thermal stability, while the metallic substrate provides ductility and structural integrity, together resisting deformation under thermal stress better than INCONEL alone

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent addresses thermal expansion by using CMC material with thermal expansion characteristics matched to the substrate, and by incorporating expansion joints or compliant layers that allow controlled movement, preventing distortion and failure under thermal cycling

Inventive Principle:

Principle #37Thermal expansion

3Temperature

If INCONEL is used, then heat-resistant performance is improved, but heat dissipation capability worsens due to low emissivity

Engineering Contradiction:

Improveheat resistanceVSAvoidheat dissipation

Core Design Contradiction:

TemperatureVSLoss of energy

Solution Approach 1:

The porous CMC structure provides internal surfaces that facilitate radiative heat transfer. The complex internal geometry of the pores increases the effective surface area for radiation, enhancing emissivity and heat dissipation compared to smooth INCONEL surfaces

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent implements transpirational cooling where coolant is pumped through channels and pores in the CMC layer. This active fluid cooling system removes heat internally and transports it away, compensating for the low emissivity of the outer surface

Inventive Principle:

Principle #29Pneumatics and hydraulics

4Temperature

If INCONEL is used, then high-temperature operation is enabled, but radar reflectivity increases

Engineering Contradiction:

Improveoperational temperature rangeVSAvoidradar reflectivity

Core Design Contradiction:

TemperatureVSObject-generated harmful factors

Solution Approach 1:

The CMC layer acts as a radar-absorbing material due to its ceramic composition and porous structure, which dissipate electromagnetic energy. This composite structure provides both high-temperature resistance and reduced radar signature, eliminating the harmful radar reflectivity of INCONEL

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 enables operation at high temperatures with reduced weight, minimizing turbulence and thermal stress, while maintaining structural integrity and efficient heat dissipation, thus addressing the limitations of existing materials.

Implementation Method 1

transpirational cooling panel comprising a porous ceramic matrix composite layer... providing efficient cooling through a porous structure

Methodology Applied

Scientific EffectEvaporative cooling: Evaporative Cooler

Implementation Method 2

transpirational cooling panel

Methodology Applied

Scientific EffectTranspiration: Transpiration

Implementation Method 3

machined ceramic fiber batting with ceramic stitching... minimizing turbulence and thermal stress

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS20240003296A1Transpirational cooling panel

Publication Date: 2024.01.04 THE BOEING CO

AI summary

A transpirational cooling panel comprises a porous ceramic matrix composite layer and a porous high-temperature fabric layer. A machined ceramic fiber batting is located between the porous ceramic matrix composite layer and the porous high-temperature fabric layer. A ceramic stitching joins the porous ceramic matrix composite layer and the porous high-temperature fabric layer through the machined ceramic fiber batting.