Ceramic composite thermal protection system

• US 9,248,923 B2
• Filed: 05/28/2014
• Issued: 02/02/2016
• Est. Priority Date: 01/12/2009
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Pinney, Thomas R., Thatcher, Conley Siddoway, Embler, Jonathan, David, Kaia Elena, Lehman, Leanne L., Zadorozny, Edward A.
• Primary Examiner(s): Michener, Joshua J
• Assistant Examiner(s): ADAMOS, THEODORE V
• Application Number:
  US14/289,609
• Publication Number:
  US 20140377510A1
• Time in Patent Office: 615 Days
• Field of Search: 524/074, 524/072, 524/042, 527/00, 527/02, 527/09, 527/180.5, 527/180.4, 525/821, 525/841, 525/861, 525/862, 525/851, 527/413, 527/450.5, 527/450.6, 527/451.3, 527/471, 524/041, 428/137, 428/163, 428/167, 428/192, 295/250.1, 244/159.1, 244/171.7
• US Class Current: 1/1
• CPC Class Codes: B64G 1/58 Thermal protection, e.g. heat shields
• CPC Class Codes: B64G 1/62 Systems for re-entry into the earth's atmosphere; Retarding or landing devices
• CPC Class Codes: Y10T 29/49947 by applying separate fastener
• CPC Class Codes: Y10T 428/24322 Composite web or sheet
• CPC Class Codes: Y10T 428/24777 Edge feature

Abstract

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.

Claims

1. An apparatus comprising:

a thermal protection element that comprises a ceramic material and an upper surface, a lower surface, and a plurality of sides;

a groove formed into the plurality of sides of the thermal protection element, such that the groove forms a single continuous depression that encompasses all of the plurality of sides and comprises a curved shape; and

a frame comprising;

four rails, each rail connected to two other rails of the four rails and respectively comprising an inner edge, and a number of tabs that extend away from the inner edge such that the inner edge of each rail comprises a shape that fills the groove such that the inner edge of each rail terminates before each end of each rail respectively such that a fastener is securable to an end of one rail and to an end of another rail.

2. The apparatus of claim 1 further comprising:

a ceramic layer covering at least the plurality of sides of the thermal protection element, wherein the ceramic layer conforms to the groove and wherein the inner edge of each rail contacts the ceramic layer within the groove, and the curved shape controls a shear load and a tension load on the ceramic layer.

3. The apparatus of claim 1, wherein the frame comprises:

the inner edge of each rail comprising a cylindrical shape;

a number of brackets; and

a number of rivets that secure the rails and the number of brackets.

4. The apparatus of claim 1, wherein the inner edge of each rail contacts the groove such that the inner edge of each rail applies a compressive load, toward a substrate within the thermal protection element, into the groove.

5. The apparatus of claim 1, wherein the thermal protection element covers an object selected from one of:

a mobile platform, an aircraft, a tank, a personnel carrier, a train, a spacecraft, a submarine, a satellite, a rocket, an engine, an engine structure, and an automobile, and the lower surface of the thermal protection element secures directly to a surface of the object.

6. The apparatus of claim 1, further comprising the frame applying a compressive load toward a substrate within the thermal protection element.

7. The apparatus of claim 1, further comprising:

the frame comprising an attachment point for a clevis that induces a tensile load on the frame; and

each of the number of tabs configured to carry greater than 30 pounds per linear inch of vertical load before failure.

8. A method for securing a thermal protection element comprising a ceramic material to a structure, the method comprising:

positioning the thermal protection element with respect to a number of fastener elements on a surface of the structure, such that the thermal protection element comprises;

a groove formed into a plurality of sides of the thermal protection element, such that the groove forms a single continuous depression that encompasses all of the plurality of sides and comprises a curved shape; and

a frame comprising;

four rails, each rail connected to two other rails of the four rails and respectively comprising an inner edge and a number of tabs that extend, away from the inner edge, the inner edge of each rail being secured to the groove via directly contacting the groove with a shape that conforms to and fills the groove; and

securing the number of tabs to the number of fastener elements on the surface of the structure, such that the inner edge of each rail terminates before each end of each rail respectively such that each end of each rail is secured to a respective end of another rail using a fastener.

9. The method of claim 8 further comprising:

forming a substrate for the thermal protection element from a ceramic matrix composite material;

placing the inner edge of each rail in the groove; and

attaching the frame to the groove.

10. The method of claim 8 further comprising:

forming a facesheet over a substrate after forming the groove and prior to placing the inner edge of each rail in the groove.

11. The method of claim 10, further comprising the groove being shaped to control a shear force and a tension force on the facesheet.

12. The method of claim 8, further comprising the groove being cylindrical, and securing a lower surface of the thermal protection element directly to a surface of the structure.

13. The method of claim 8, further comprising attaching the frame to the groove via a clevis that induces a tensile load on the frame and a compressive load into a substrate within the thermal protection element.

14. A method for securing a thermal protection element comprising a ceramic material to a structure, the method comprising:

positioning the thermal protection element with respect to a number of fastener elements on a surface of the structure, such that the thermal protection element comprises;

a groove formed into a plurality of sides of the thermal protection element, such that the groove forms a single continuous depression that encompasses all of the plurality of sides and comprises a curved shape; and

a frame comprising;

four rails, each rail connected to two other rails of the four rails and respectively comprising an inner edge and a number of tabs that extend, substantially perpendicular to a side of the plurality of sides, and away from the inner edge, the inner edge of each rail being secured to the groove via directly contacting the groove with a shape that conforms to and fills the groove;

securing a lower surface of the thermal protection element directly to a surface of the structure; and

securing the number of tabs to the number of fastener elements on the surface of the structure, such that the inner edge of each rail terminates before each end of each rail respectively such that each end of each rail is secured to a respective end of another rail using a fastener.