Three-dimensional multi-shell insulation

• US 10,408,378 B2
• Filed: 07/17/2017
• Issued: 09/10/2019
• Est. Priority Date: 07/17/2017
• Status: Active Grant

• Current Assignee: Raytheon Company (Rtx Corporation)
• Original Assignee: Raytheon Company (Rtx Corporation)
• Inventors: Fiedler, Tracy M., Ketola, Kurt S., Truxel, Andrew
• Primary Examiner(s): Raymond, Keith M
• Assistant Examiner(s): Jones, Gordon A
• Application Number:
  US15/651,440
• Publication Number:
  US 20190017645A1
• Time in Patent Office: 785 Days
• CPC Class Codes: B22F 10/25 Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/40 Structures for supporting workpieces or articles during manufacture and removed afterwards
• CPC Class Codes: B22F 7/06 of composite workpieces or articles from parts, e.g. to form tipped tools B22F7/002 takes precedence
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: B64G 1/50 for temperature control
• CPC Class Codes: B64G 1/58 Thermal protection, e.g. heat shields
• CPC Class Codes: F16L 59/029 layered
• CPC Class Codes: F16L 59/08 Means for preventing radiation, e.g. with metal foil
• CPC Class Codes: F16L 59/12 Arrangements for supporting insulation from the wall or body insulated, e.g. by means of spacers between pipe and heat-insulating material; Arrangements specially adapted for supporting insulated bodies
• CPC Class Codes: F16L 59/161 Housings for valves, tee pieces, or the like
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

A three-dimensional multi-shell insulation configured to conform to the shape of a spacecraft component to be insulated. The insulation may have a plurality of nested shell layers that are displaceable relative to each other for providing natural separation between the shell layers when the insulation is used in low-pressure and/or low-gravity space-related applications. To establish the spacing between shell layers, an edge clamp may be operatively coupled to an edge portion on at least one side of each shell layer. The shell layers may have sufficient flexibility and/or may be sufficiently displaceable relative to each other to allow the insulation to be installed or removed from the spacecraft component. One or more restraints may be provided in the space between the shell layers for restricting the relative lateral and/or transverse movement between shell layers for preventing contact. Additive manufacturing may be employed to fabricate the insulation and integrate features.

Claims

1. A three-dimensional multi-shell insulation for insulating at least one portion of a spacecraft, the insulation comprising:

a plurality of nested shell layers of progressively increasing size that are configured to at least partially surround the at least one portion of the spacecraft, each of the plurality of shell layers having layer edge portions on opposite sides of said each of the plurality of the shell layers, and said each of the plurality of shell layers having a layer major portion extending between the layer edge portions; and

at least one edge clamp operatively coupled to the plurality of shell layers at the respective layer edge portions on at least one side of the shell layers;

wherein each layer major portion has at least one layer major surface configured to be spaced apart from an opposing layer major surface of an adjacent shell layer for minimizing thermal conduction between the shell layers; and

wherein the respective layer major surfaces of each of the plurality of nested shell layers are configured to be spaced apart when the insulation is in use in a low-gravity and/or low-pressure environment;

wherein the at least one edge clamp is configured to maintain spacing between the respective layer major surfaces of the shell layers when the insulation is in use in a low-gravity and/or low-pressure environment; and

wherein each of the layer major portions of the plurality of shell layers has at least one abutment, the respective abutments of the adjacent shell layers being configured to provide a stop when engaging each other, thereby restricting the amount of relative lateral displacement between the adjacent shell layers.

2. The three-dimensional multi-shell insulation according to claim 1, wherein the plurality of nested shell layers have sufficient flexibility to enable the layer edge portions on opposite sides of the shell layers to be movable relative to each other, such that the insulation is flexibly wrappable around the at least one portion of the spacecraft, thereby allowing the insulation to be installed and at least partially surround the at least one portion of the spacecraft for insulating the at least one portion of the spacecraft, and allowing the insulation to be removed from the at least one portion of the spacecraft for enhancing access to the at least one portion of the spacecraft.

3. The three-dimensional multi-shell insulation according to claim 1, wherein each of the layer major portions of the plurality of shell layers are displaceable relative to each other for enhancing the flexibility of the insulation.

4. The three-dimensional multi-shell insulation according to claim 1, wherein the at least one abutment of each shell layer is independent of the adjacent shell layer for enabling the respective layer major portions of the plurality of shell layers to be displaceable relative to each other, thereby enhancing the flexibility of the insulation and minimizing thermal conduction between shell layers.

5. The three-dimensional multi-shell insulation according to claim 1,

wherein the at least one abutment of each shell layer is integrally formed with the shell layer, and is made of the same material as the shell layer;

or

wherein the at least one abutment of each shell layer is operatively coupled to the shell layer, and is made of a different material than the shell layer.

6. The three-dimensional multi-shell insulation according to claim 1, wherein the at least one abutment of one shell layer is laterally offset from the at least one abutment on an opposing surface of the adjacent shell layer.

7. The three-dimensional multi-shell insulation according to claim 1, wherein the at least one edge clamp includes at least two edge clamps laterally spaced apart along the at least one side of the shell layers to provide at least one passage in fluid communication with the space between at least two of the shell layers, the at least one passage enabling venting of fluid from between the at least two shell layers.

8. The three-dimensional multi-shell insulation according to claim 1, wherein the at least one edge clamp{[s]} on one or more sides of the shell layers is the only mechanism for coupling the plurality of shell layers together.

9. The three-dimensional multi-shell insulation according to claim 1, wherein the edge clamp has at least one fastener for removably attaching the insulation to at least one portion of the spacecraft.

10. The three-dimensional multi-shell insulation according to claim 1, wherein the edge clamp has a ground wire integrated therein.

11. The three-dimensional multi-shell insulation according to claim 1, wherein each of the plurality of shell layers has at least one bend for at least partially surrounding the at least one portion of the spacecraft in three-dimensions.

12. The three-dimensional multi-shell insulation according to claim 11, wherein each of the plurality of shell layers is unitary.

13. The three-dimensional multi-shell insulation according to claim 1, wherein each of the plurality of shell layers has a thickness less than 0.13 mm.

14. The three-dimensional multi-shell insulation according to claim 1, wherein each of the plurality of nested shell layers is formed by additive manufacturing such that the insulation essentially conforms to the shape of the at least one portion of the spacecraft to be insulated.

15. The three-dimensional multi-shell insulation according to claim 1, wherein each of the plurality of shell layers is made of a polymeric material.

16. The three-dimensional multi-shell insulation according to claim 1, wherein each of the plurality of shell layers is metallized with a low emissivity coating.