Multi-layer Thermal Protection System for Hypersonic Vehicles

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

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 being inefficient in heat management due to their thickness and material composition.

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, a phase change insulation layer, and an inboard facesheet layer, with a structural system of truss pins for support, which allows for efficient heat dissipation and reduced weight and volume.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a thick plate made of bonded ceramic insulating foam tile, ceramic, or metallic standoff panel with insulating blanket is used for thermal protection, then the vehicle is well insulated from heat, but the weight of the plate becomes very heavy and the internal volume for other components decreases

Engineering Contradiction:

Improveheat insulationVSAvoidweight of thermal protection plate

Core Design Contradiction:

TemperatureVSWeight of moving object

Solution Approach 1:

The thermal protection system is divided into multiple discrete layers including outer facesheet, passive insulation layer, phase change insulation layer, and inner facesheet. Each layer performs a specific thermal function, allowing the system to achieve effective heat protection with reduced overall thickness and weight compared to conventional single-plate designs.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system combines different material types in a composite structure: ceramic matrix composite facesheets for structural integrity and heat resistance, passive insulation materials for thermal barrier properties, and phase change insulation materials for active heat absorption. This multi-material composite approach optimizes the weight-to-protection ratio.

Inventive Principle:

Principle #40Composite materials

2Temperature

If a thick plate is used for thermal protection, then the vehicle is well insulated from heat, but the thickness increases and internal volume for other components decreases

Engineering Contradiction:

Improveheat insulationVSAvoidinternal volume of vehicle

Core Design Contradiction:

TemperatureVSVolume of moving object

Solution Approach 1:

By segmenting the thermal protection into multiple thin layers rather than one thick plate, the system achieves the same thermal protection performance with reduced overall thickness. The layered structure includes outer facesheet (0.5-5mm), passive insulation layer (5-50mm), phase change insulation layer (2-25mm), and inner facesheet (0.5-5mm), totaling less thickness than conventional single-plate designs.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The phase change insulation layer utilizes phase transition phenomena to absorb and dissipate heat energy, providing effective thermal protection with a thinner layer compared to passive insulation alone. This allows reduction in overall system thickness while maintaining or improving heat protection performance.

Inventive Principle:

Principle #36Phase transitions

3Temperature

If conventional thermal protection materials are used, then heat protection is achieved, but the system is inefficient in heat management due to thickness and material composition

Engineering Contradiction:

Improveheat protectionVSAvoidheat management efficiency

Core Design Contradiction:

TemperatureVSProductivity

Solution Approach 1:

The phase change insulation layer actively manages heat by utilizing phase transition phenomena, absorbing excess heat during phase change and releasing it when needed. This active thermal regulation improves heat management efficiency compared to passive insulation materials that merely resist heat flow.

Inventive Principle:

Principle #36Phase transitions

Solution Approach 2:

The system changes the thermal parameters of the protection system by incorporating materials with different thermal properties at different layers. The outer facesheet has high heat resistance, the passive insulation provides thermal barrier, and the phase change layer provides dynamic thermal regulation, creating an optimized thermal management system.

Inventive Principle:

Principle #35Parameter changes

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 the performance of hypersonic vehicles by effectively managing heat through passive and phase change insulation, and maintaining structural integrity.

Implementation Method 1

A second layer includes a phase change insulation material

Methodology Applied

Scientific EffectPhase change: Phase Change

Implementation Method 2

A second layer includes a phase change insulation material

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

PatentUS9475261B2Dual 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. A structural system extends through the first layer, the second layer, the third layer, or a combination thereof.