Protective Casing Using Microlattice and Phase Change Material

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Solution Overview

Problem

Existing protective enclosures for data gathering instruments and humans in extreme environments are inefficient due to uneven distribution of insulation and heat absorbing materials, leading to increased weight and size from heavy-gauge steel, which compromises protection against shocks, heat, and liquids.

Innovation Solution

A protective casing comprising a flexible insulation layer, a microlattice layer with heat absorbing material, and an outer protective layer that distributes thermal energy and absorbs shocks, reducing the need for heavy steel and optimizing weight and size while maintaining robustness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If heavy-gauge hardened steel is used to protect against shocks, then protection against extreme conditions is improved, but weight increases significantly

Engineering Contradiction:

Improveprotection against extreme conditionsVSAvoidweight of protective covering

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent employs a composite structure combining multiple materials: a flexible insulation layer (aerogel or foam), a microlattice layer (metallic or polymer-based porous structure), and heat absorbing material (phase change material). This composite approach replaces the single-material heavy-gauge steel solution with a multi-material system that achieves equivalent or superior protection against shocks, heat, and liquids while significantly reducing weight.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies different materials with specific properties to different regions and functions within the protective covering. The flexible insulation layer provides thermal isolation, the microlattice layer provides shock absorption and structural integrity, and the heat absorbing material handles thermal energy. This localized optimization allows each material to perform its specialized function efficiently, reducing the need for excessive steel throughout the entire structure.

Inventive Principle:

Principle #3Local quality

2Reliability

If insulation and heat absorbing material are evenly distributed, then protection efficiency is improved, but device complexity increases due to optimization constraints

Engineering Contradiction:

Improveprotection efficiencyVSAvoidenclosure geometry optimization

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent divides the protective covering into distinct functional layers: an outer flexible insulation layer, a middle microlattice layer, and an inner heat absorbing material layer. This segmentation allows for even distribution of protective properties across the structure while simplifying the design process compared to attempting to optimize a single monolithic steel enclosure. Each layer can be independently designed and manufactured, reducing overall complexity.

Inventive Principle:

Principle #1Segmentation

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 protects against extreme conditions such as aircraft crashes by distributing thermal energy and absorbing shocks, reducing weight and size while maintaining structural integrity and protection against heat, shocks, and liquids.

Implementation Method 1

a flexible insulation layer configured to inhibit thermal energy from conducting from an external side of the flexible insulation layer to an internal side of the flexible insulation layer

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 2

a microlattice layer abutting the internal side of the flexible insulation layer, the microlattice layer configured to distribute thermal energy that passes through the flexible insulation layer substantially throughout the microlattice layer

Methodology Applied

Scientific EffectThermal energy distribution: Conduction (thermal)

Implementation Method 3

a heat absorbing material that impregnates the microlattice layer, the heat absorbing material configured to absorb the thermal energy in the microlattice layer

Methodology Applied

Scientific EffectHeat absorption: Absorption (physical)

Data Source

PatentUS8859063B2Systems and methods for a protective casing

Publication Date: 2014.10.14 HONEYWELL INTERNATIONAL INC

AI summary

Systems and methods for a protective casing are provided. In at least one embodiment, a protective casing includes a flexible insulation layer configured to inhibit thermal energy from conducting from an external side of the flexible insulation layer to an internal side of the flexible insulation layer. The protective casing also includes a microlattice layer abutting the internal side of the flexible insulation layer, the microlattice layer configured to distribute thermal energy that passes through the flexible insulation layer substantially throughout the microlattice layer. Further, the protective casing includes a heat absorbing material that impregnates the microlattice layer, the heat absorbing material configured to absorb the thermal energy in the microlattice layer.