Spacecraft Protective Blanket Using Carbon Nanotube Composites

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Solution Overview

Problem

The high cost of launching spacecraft and the vulnerability of electronic equipment to space debris and electromagnetic interference (EMI) necessitate a lightweight protective solution that provides thermal, ballistic, and EMI protection.

Innovation Solution

A protective blanket composed of multiple sheets of materials, including carbon nanotube reinforced composite, polyaramid or polyimide, and metal mesh, layered and coupled together to conform to the spacecraft body, offering thermal, ballistic, and EMI protection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional protective materials are used for spacecraft, then protection against space debris and EMI is provided, but the mass of the spacecraft increases significantly

Engineering Contradiction:

Improveprotection against space debris and EMIVSAvoidmass of spacecraft

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent employs a multi-layer composite structure combining carbon nanotube-reinforced polymer sheets with polyaramid or polyimide sheets. The carbon nanotubes provide exceptional strength-to-weight ratio and electromagnetic interference shielding, while the polymer matrix provides structural integrity. This composite approach achieves superior protection performance with reduced mass compared to traditional solid metal shields.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The protective blanket utilizes thin-film technology with sheets having thicknesses in the range of 10-100 micrometers. These flexible thin films are operatively coupled together to form a lightweight protective barrier that conforms to spacecraft surfaces, providing EMI shielding and debris protection without the mass penalty of rigid traditional shielding materials.

Inventive Principle:

Principle #30Flexible shells and thin films

2Strength

If thicker protective layers are used to protect against space debris, then ballistic protection is improved, but the mass and volume of the spacecraft increase

Engineering Contradiction:

Improveballistic protectionVSAvoidmass of spacecraft

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The multi-layer composite structure with carbon nanotube-reinforced sheets provides enhanced ballistic protection through the unique properties of carbon nanotubes, which have exceptional tensile strength and energy absorption characteristics. The composite architecture allows for optimized protection performance with minimal thickness and mass compared to traditional monolithic protective materials.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the material parameters by incorporating carbon nanotubes at specific concentrations (0.1-10 wt%) within the polymer matrix, fundamentally altering the mechanical and protective properties of the sheets. This parameter optimization enables high-strength ballistic protection with dramatically reduced material thickness and mass.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If traditional EMI shielding materials are used, then electromagnetic interference protection is provided, but the cost and mass of the spacecraft increase

Engineering Contradiction:

ImproveEMI protectionVSAvoidmass of spacecraft

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The carbon nanotube-reinforced polymer sheets inherently provide electromagnetic interference shielding through the conductive network formed by carbon nanotubes. This composite material integrates EMI protection functionality directly into the structural protective layers, eliminating the need for separate heavy metal EMI shielding layers and reducing overall spacecraft mass.

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 significantly reduces the mass of the spacecraft while effectively protecting against space debris and electromagnetic interference, enhancing the durability and functionality of electronic equipment.

Implementation Method 1

at least one sheet composed of carbon nanotube reinforced composite material

Methodology Applied

Scientific EffectCarbon nanotube reinforcement: Carbon Nanotubes

Implementation Method 2

at least one sheet composed of metal mesh

Methodology Applied

Scientific EffectElectromagnetic shielding: Faraday Cage

Implementation Method 3

at least one sheet composed at least in part of polyaramid or polyimide material

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentEP3042760B1Spacecraft and spacecraft protective blankets

Publication Date: 2022.04.13 THE BOEING CO

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AI summary

Protective blankets include a plurality of sheets of material operatively coupled together to define the protective blanket. The plurality of sheets includes at least one sheet composed of carbon nanotube reinforced composite material and at least one sheet composed of a different material. Methods of assembling protective blankets include layering the plurality of sheets and operatively coupling together the plurality of sheets. Spacecraft include a body and a protective blanket operatively coupled to the body. Methods of assembling spacecraft include coupling a protective blanket to the body of a spacecraft.