Multi-functional composite structure for extreme environments

• US 10,442,559 B2
• Filed: 08/02/2016
• Issued: 10/15/2019
• Est. Priority Date: 08/02/2016
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Dong, Jian, Hussain, Naveed Moayyed
• Primary Examiner(s): Benedik, Justin M
• Application Number:
  US15/226,219
• Publication Number:
  US 20180037342A1
• Time in Patent Office: 1,169 Days
• CPC Class Codes: B32B 1/08 Tubular products
• CPC Class Codes: B32B 15/02 Layer formed of wires, e.g. mesh
• CPC Class Codes: B32B 2250/05 5 or more layers
• CPC Class Codes: B32B 2250/40 Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
• CPC Class Codes: B32B 2262/0253 Polyolefin fibres vinyl or acrylic copolymers B32B2262/0223 or B32B2262/0246
• CPC Class Codes: B32B 2262/0269 Aromatic polyamide fibres
• CPC Class Codes: B32B 2262/105 Ceramic fibres
• CPC Class Codes: B32B 2262/106 Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2262/14 Mixture of at least two fibres made of different materials
• CPC Class Codes: B32B 2266/0278 Polyurethane
• CPC Class Codes: B32B 2307/202 Conductive
• CPC Class Codes: B32B 2307/212 Electromagnetic interference shielding
• CPC Class Codes: B32B 2307/304 Insulating
• CPC Class Codes: B32B 2307/558 Impact strength, toughness
• CPC Class Codes: B32B 2307/56 Damping, energy absorption
• CPC Class Codes: B32B 2307/71 Resistive to light or to UV
• CPC Class Codes: B32B 2307/7246 Water vapor barrier
• CPC Class Codes: B32B 2571/02 defensive, e.g. armour plates, anti-ballistic clothing camouflage nets B32B2459/00
• CPC Class Codes: B32B 2605/00 Vehicles
• CPC Class Codes: B32B 2605/18 Aircraft blades, propellers B32B2603/00
• CPC Class Codes: B32B 27/065 : of foam
• CPC Class Codes: B32B 27/12 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/32 : comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 3/08 : characterised by added members at particular parts layer formed of separate pieces of material which are juxtaposed side-by-side B32B3/14, B32B3/18
• CPC Class Codes: B32B 3/12 : characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
• CPC Class Codes: B32B 5/02 : characterised by structural features of a fibrous or filamentary layer layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: B32B 9/007 : comprising carbon, e.g. graphite, composite carbon
• CPC Class Codes: B64C 1/064 : Stringers; Longerons
• CPC Class Codes: B64C 1/066 : Interior liners
• CPC Class Codes: B64C 1/12 : Construction or attachment of skin panels
• CPC Class Codes: B64C 1/406 : in combination with supports for lines, e.g. for pipes or cables
• CPC Class Codes: B64C 2001/0072 : from composite materials
• CPC Class Codes: B64D 2221/00 : Electric power distribution systems onboard aircraft
• CPC Class Codes: B64G 1/10 : Artificial satellites; Systems of such satellites; Interplanetary vehicles space shuttles B64G1/14
• CPC Class Codes: B64G 1/54 : Protection against radiation
• CPC Class Codes: B64G 1/56 : Protection against meteoroids or space debris
• CPC Class Codes: E04B 1/92 : Protection against other undesired influences or dangers buildings providing protection against external dangers E04H9/00; shielding against dangerous radiation G21F
• CPC Class Codes: E04B 2001/925 : Protection against harmful electro-magnetic or radio-active radiations, e.g. X-rays
• CPC Class Codes: E04C 2/284 : at least one of the materials being insulating
• CPC Class Codes: E04C 2/3405 : spaced apart by profiled spacer sheets
• CPC Class Codes: E04C 2/365 : by honeycomb structures
• CPC Class Codes: E04C 2/521 : serving for locating conduits; for ventilating, heating or cooling
• CPC Class Codes: E04C 2/526 : with adaptations not otherwise provided for, for connecting, transport; for making impervious or hermetic, e.g. sealings
• CPC Class Codes: E04C 2002/345 : with triangular corrugations
• CPC Class Codes: Y02T 50/40 : Weight reduction

Abstract

A multi-functional composite structure has a modular design that can be altered depending on an extreme environment in which the structure will be exposed such as hazardous radiation, micro-meteoroid and orbital debris impacts, extreme temperature changes, etc. The material combinations employed in the multi-functional composite structure provide a supporting structure with low weight and maximum protection from radiation, debris impacts and temperature variations.

Claims

1. A composite structure comprising:

an outer panel, the outer panel being constructed of a composite material, the composite material is comprised of multiple layers of sheets having a hydrogen content that provides radiation protection, thermal insulation and structural strength, the outer panel having a thickness between an exterior surface of the outer panel and an interior surface of the outer panel, the exterior surface of the outer panel and the interior surface of the outer panel being smooth, continuous surfaces that are substantially parallel;

an inner panel, the inner panel being constructed of a composite material, the composite material is comprised of multiple layers of sheets having a hydrogen content that provides radiation protection, thermal insulation and structural strength, the inner panel having a thickness between an exterior surface of the inner panel and an interior surface of the inner panel, the exterior surface of the inner panel and the interior surface of the inner panel being smooth, continuous surfaces that are substantially parallel;

a space between the interior surface of the outer panel and the interior surface of the inner panel;

a support structure in the space, the support structure being connected to the interior surface of the outer panel and the interior surface of the inner panel;

a foam interposed in the space and the support structure; and

,

a wire extending through the space between the interior surface of the outer panel and the interior surface of the inner panel, the wire having a high electrical conductivity.

2. The composite structure of claim 1, further comprising:

insulation in the space between the interior surface of the outer panel and the interior surface of the inner panel, the insulation being multi-layer insulation, the multi-layer insulation extending across the interior surface of the inner panel.

3. The composite structure of claim 2, further comprising:

the insulation being thermal insulation and the insulation being radiation shielding insulation.

4. The composite structure of claim 1, further comprising:

the wire having a helix configuration that extends through the space between the interior surface of the outer panel and the interior surface of the inner panel.

5. The composite structure of claim 1, further comprising:

the support structure having a lattice configuration comprised of a plurality of walls that are connected to the interior surface of the outer panel and the interior surface of the inner panel, the plurality of walls extending between a plurality of divided spaces between the interior surface of the outer panel and the interior surface of the inner panel with the plurality of walls separating the plurality of divided spaces; and

,

the foam filling the plurality of divided spaces between the interior surface of the outer panel and the interior surface of the inner panel.

6. The composite structure of claim 5, further comprising:

the plurality of walls giving each of the plurality of divided spaces a honeycomb configuration.

7. The composite structure of claim 5, further comprising:

the plurality of walls giving each of the plurality of divided spaces a trapezoidal configuration.

8. The composite structure of claim 1, further comprising:

the composite material of the outer panel being selected from a group comprising Kevlar 49, fiberglass, boron carbide, Spectra Fiber, Nextel fabric, graphite/epoxy fabric, Spectra Fiber/polyethylene, graphite/epoxy tape, and graphite/Spectra/high density polyethylene laminate; and

,

the composite material of the inner panel being selected from a group comprising Kevlar 49, fiberglass, boron carbide, Spectra Fiber, Nextel fabric, graphite/epoxy fabric, Spectra Fiber/polyethylene, graphite/epoxy tape, and graphite/Spectra/high density polyethylene laminate.

9. The composite structure of claim 1, further comprising:

the thickness of the outer panel being in a range of 0.2 cm to 2.0 cm; and

,

the thickness of the inner panel being in a range of 0.2 cm to 2.0 cm.

10. The composite structure of claim 9, further comprising:

the space between the interior surface of the outer panel and the interior surface of the inner panel being in a range of 5 cm to 10 cm.

11. A composite structure comprising:

an outer panel, the outer panel being constructed of a composite material, the composite material is comprised of multiple layers of sheets having a hydrogen content that provides radiation protection, thermal insulation and structural strength, the outer panel having a thickness between an exterior surface of the outer panel and an interior surface of the outer panel, the exterior surface of the outer panel and the interior surface of the outer panel being smooth, continuous surfaces and being substantially parallel;

an inner panel, the inner panel being constructed of a composite material, the composite material is comprised of multiple layers of sheets having a hydrogen content that provides radiation protection, thermal insulation and structural strength, the inner panel having a thickness between an exterior surface of the inner panel and an interior surface of the inner panel, the exterior surface of the inner panel and the interior surface of the inner panel being smooth, continuous surfaces and being substantially parallel;

a space between the interior surface of the outer panel and the interior surface of the inner panel;

a support structure in the space, the support structure being connected to the interior surface of the outer panel and the interior surface of the inner panel, the support structure having a lattice configuration comprised of a plurality of walls that are connected to the interior surface of the outer panel and the interior surface of the inner panel, the plurality of walls extending between a plurality of divided spaces between the interior surface of the outer panel and the interior surface of the inner panel with the plurality of walls separating the plurality of divided spaces;

a foam filling the plurality of divided spaces between the interior surface of the outer panel and the interior surface of the inner panel; and

,

a wire extending through the space between the interior surface of the outer panel and the interior surface of the inner panel, the wire having high electrical conductivity.

12. The composite structure of claim 11, further comprising:

insulation in the space between the interior surface of the outer panel and the interior surface of the inner panel, the insulation being multi-layer insulation, the multi-layer insulation extending across the interior surface of the inner panel.

13. The composite structure of claim 12, further comprising:

the insulation being thermal insulation and the insulation being radiation shielding insulation.

14. The composite structure of claim 11, further comprising:

the wire having a helix configuration that extends through the space between the interior surface of the outer panel and the interior surface of the inner panel.

15. The composite structure of claim 11, further comprising:

the plurality of walls giving each of the plurality of divided spaces a honeycomb configuration.

16. The composite structure of claim 11, further comprising:

the plurality of walls giving each of the plurality of divided spaces a trapezoidal configuration.

17. The composite structure of claim 11, further comprising:

the composite material of the outer panel being selected from a group comprising Kevlar 49, fiberglass, boron carbide, Spectra Fiber, Nextel fabric, graphite/epoxy fabric, Spectra Fiber/polyethylene, graphite/epoxy tape, and graphite/Spectra/high density polyethylene laminate; and

,

the composite material of the inner panel being selected from a group comprising Kevlar 49, fiberglass, boron carbide, Spectra Fiber, Nextel fabric, graphite/epoxy fabric, Spectra Fiber/polyethylene, graphite/epoxy tape, and graphite/Spectra/high density polyethylene laminate.

18. The composite structure of claim 11, further comprising:

the thickness of the outer panel being in a range of 0.2 cm to 2.0 cm; and

,

the thickness of the inner panel being in a range of 0.2 cm to 2.0 cm.

19. The composite structure of claim 18, further comprising:

the space between the interior surface of the outer panel and the interior surface of the inner panel being in a range of 5 cm to 10 cm.

20. A method of constructing a composite structure of a spacecraft comprising:

constructing a spacecraft with an inner panel that extends around an interior volume of the spacecraft and an outer panel that extends around the inner panel;

constructing the outer panel of composite material selected from a group comprising Kevlar 49, fiberglass, boron carbide, Spectra Fiber, Nextel fabric, graphite/epoxy fabric, Spectra Fiber/polyethelene, graphite/epoxy tape, and graphite/Spectra/high density polyethylene laminate, the composite material being multiple layers of sheets having a hydrogen content that provides radiation protection, thermal insulation and structural strength;

constructing the inner panel of composite material selected from a group comprising Kevlar 49, fiberglass, boron carbide, Spectra Fiber, Nextel fabric, graphite/epoxy fabric, Spectra Fiber/polyethylene, graphite/epoxy tape, and graphite/Spectra/high density polyethylene laminate, the composite material being multiple layers of sheets having a hydrogen content that provides radiation protection, thermal insulation and structural strength;

providing a space between the outer panel and the inner panel;

positioning a support structure in the space and connecting the support structure to the outer panel and the inner panel;

interposing foam in the space and the support structure; and

,

extending wire through the space with the wire configured in a helix configuration; and

,

connecting a power source to the wire.

21. A method of shielding a spacecraft from radiation comprising:

subjecting a spacecraft to an extreme environment of space where the spacecraft is constructed with an inner panel extending around an interior volume of the spacecraft and an outer panel extending around the inner panel with a space between the inner panel and the outer panel;

constructing the inner panel of composite material comprised of multiple layers of sheets having a hydrogen content that provides radiation protection, thermal insulation and structural strength;

constructing the outer panel of composite material comprised of multiple layers of sheets having a hydrogen content that provides radiation protection, thermal insulation and structural strength;

positioning an electrical conductor haying a length with opposite first and second ends in the spacecraft with the length of the electrical conductor extending in a helix configuration from the first end of the electrical conductor to the second end of the electrical conductor around the spacecraft;

directing a flow of electric current through the length of the electrical conductor from the first end of the electrical conductor to the second end of the electrical conductor;

creating a magnetic field in the space by the flow of electric current directed through the length of the electrical conductor; and

,

repelling radiation with the magnetic field created in the space thereby shielding the structure from radiation.