The Boeing Company

Leanne L Lehman

Jonathan David Embler

Thomas R Pinney

Vann Heng

Buddhadev Chakrabarti

Kaia Elena David

Michael Leslie Hand

William Preston Keith

Conley Siddoway Thatcher

Edward A Zadorozny

Sangvavann Heng

James Philip Ledesma, Jr

Robert A DiChiara

Gopal Prasad Mathur

Winnie W Chen

Jerry Denham

David Zorger

Richard Philip Topf

Ali Yousefiani

Adam J Lang

Patrick Jacob Mobers

Miklos Paul Petervary

Steffan Brown

Mark D Gilcreest

Eric Winter

Mary Margaret Litwinski

Van Ha Ngo

Matthew J Woerly

William C Cromer

Merna E Salama

Kenneth R Stempel

Dan E Driemeyer

Ryan J Clabots

Michael L Hand

Gopal P Mathur

William P Keith

John R Mccann

Chakrabarti Buddhadev

There is provided a heat shield for an aircraft. The heat shield has a pair of side skins. Each side skin is formed of a heat resistant material and has a side skin edge. The heat shield further has a lower skin formed of a heat resistant material and having lower skin edges. The lower skin edges extend an extended length past the side skin edges. The lower skin edges are separate from the side skin edges. A gap is formed between the side skin edges and the lower skin. The lower skin is configured to thermally expand without contacting the pair of side skins. The heat shield further has a plurality of frame members attached to the lower skin. The heat shield further has an air ingress restrictor assembly associated with one of, the pair of side skins, or the lower skin.

Heat shield for an aircraft and method of using the same

A thermal protection system is provided for a vehicle substructure. The thermal protection system comprises an outer layer for protecting the vehicle substructure. The thermal protection system further comprises an inner layer for conforming to the vehicle substructure. The thermal protection system also comprises an insulation layer sandwiched between the inner and outer layers. The insulation layer includes a porous low-density ceramic insulating material having a densified portion that covers an inner surface of the outer layer to strengthen adhesion.

Rigidized hybrid insulating non-oxide thermal protection system and method of producing a non-oxide ceramic composite for making the same

A continuous ceramic matrix composite strip is produced by passing a dry ceramic fiber strip through a ceramic slurry bath. Impregnation wheels within the bath guide the fiber strip through the bath and force the ceramic slurry into the fiber strip, thereby impregnating the strip. The impregnation wheels stir the ceramic slurry to maintain a homogeneous mixture. Air knives remove excess slurry from the strip. Thickness and width controls squeeze the impregnated strip to desired thickness and width dimensions.

Method and apparatus for impregnating a continuous fiber reinforcement

A CMC sandwich used to fabricate CMC structures includes facesheets bonded to a core reinforced with a ceramic truss comprising an array of CMC pins. The binder matrix in the ends of the pins is removed, leaving exposed, flexible ceramic fibers. The exposed ceramic fibers are bent so as to extend parallel to the facesheets, and are bonded to one or more plies of the facesheets. The binder matrix in the ends of the ceramic pins may be removed by mechanical or chemical processes.

Composite structure having ceramic truss core and method for making the same

A method for reworking a ceramic structure. A portion of a first facesheet is removed from the ceramic structure to form a first aperture. The first facesheet comprises a number of layers of a first ceramic material. A portion of an inner section of the ceramic structure is removed to form a second aperture. The second aperture extends from the first aperture into the inner section. The inner section comprises a second ceramic material bonded to the first facesheet and has a lower density than the first facesheet. A ceramic replacement material is placed in the second aperture. A number of replacement ceramic layers are placed in the first aperture. Ceramic particles are placed between the first facesheet and the number of replacement ceramic layers. The ceramic particles are sintered to bond the number of replacement ceramic layers to the first facesheet.

Reworking ceramic sandwich structures

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.

Dual layer sandwich for thermal management

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.

An apparatus comprises a thermal protection element, a number of washers, a ceramic layer, a number of blind fasteners, and a number of tabs. The thermal protection element has an upper surface, a lower surface, and a plurality of sides. The ceramic layer covers at least the plurality of sides of the thermal protection element. The number of tabs is connected to the number of sides by the number of blind fasteners secured to the ceramic layers. The tabs may be part of a frame secured to a groove around the plurality of sides.

Ceramic composite thermal protection system

High-temperature fabrics with a coatings to provide oxidation protection at high temperatures, and capable of being formed into a variety of softgoods parts, and methods for their manufacture are disclosed.

Re-usable high-temperature resistant softgoods for aerospace applications

A method for adding insulation or bulk absorbers into high temperature sandwich structures following fabrication is presented. A slurry of ceramic fibers and/or particles, opacified particles, fugitive fibers, organic binders and inorganic binders is prepared as an aqueous solution. The slurry is cast within a prepared sandwich structure, dried, and heated to form a low density ceramic core material to provide insulation or noise absorption. Following incorporation of the ceramic material, aerogels or phase change materials may also be added to provide additional thermal management benefits.

Method for incorporation of insulators and bulk absorbers in high temperature sandwich structures after fabrication

A laminated ceramic matrix composite structure is strengthened with one or more layers of a metal reinforcement. The metal reinforcement is selected to provide optimal strength and thermal compatibility with the ceramic matrix composite. The metal reinforcement includes an outer oxidized layer that bonds to the ceramic matrix composite. It may also include a barrier layer on the surface of the metal that helps prevent further oxidation. The structure is formed using standard composite prepreg layup techniques.

Method for making hybrid metal-ceramic matrix composite structures and structures made thereby

A blanket assembly includes a shear fabric and an attachment frame wrapped in the shear fabric. A thermal protection blanket is carried by the shear fabric.

Thermal protection blanket assembly

A composite structure and an associated exhaust washed structure are provided which may be formed of ceramic matrix composite (CMC) materials. A method of fabricating a composite structure which may include the CMC material is also provided. A composite structure may include a corrugated septum extending in a lengthwise direction. The composite structure may also include a flute within which the corrugated septum is disposed to form, for example, a partitioned flute assembly.

Exhaust washed structure and associated composite structure and method of fabrication

A ceramic matrix composite structure has a reinforced core for carrying loads. The core includes a web connected between the facesheets by edge bonded joints for transmitting compressive, tensile and shear loads. The edge bonded joints are laterally reinforced by bridging members bonded to the facesheets, on opposite sides of the webs The bridging members may comprise low density, high temperature rigid foam.

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Aliso Viejo, CA, United States of America

Leanne L Lehman