Composite components with integral protective casings

Abstract

Methods and compositions for fabricating composite parts including at least one structural material and at least one protective material that are integrally bonded without the use of secondary bonding operations. One or more of the materials forming the layers of the composite parts may be a ceramic composition with or without porosity and one or more of the materials may be a polymer composition. Methods including co-injection processes also are provided for fabricating multi-layered structures in which each layer serves a desired function while still being integrated into the overall structure.

Description

CROSS REFERENCE TO RELATED APPLICATIONS[0001]This application is a divisional of U.S. patent application Ser. No. 10 / 293,852, filed on Nov. 12, 2002, entitled “Composite Components with Integral Protective Casings,” which claims the benefit of U.S. Provisional Application No. 60 / 344,936, filed on Nov. 9, 2001, and entitled “Composite Casings with Integral Heating Shields”, now abandoned, both of which applications are incorporated herein by reference.[0002]The present invention was made with U.S. Government support under SBIR Grants #F04611-01-C-0058 and DASG60-02-P-0234 awarded by the Air Force and the Army, respectively. Accordingly, the U.S. Government may have certain rights in the invention described herein.FIELD OF THE INVENTION[0003]The present invention relates to structural composite components. More particularly, this invention relates to lightweight ceramic structures having integral insulating layers for thermal protection in high temperature applications, such as in tur...

AI Technical Summary

Benefits of technology

The solution provides enhanced structural integrity, fire resistance, and reduced maintenance costs by eliminating delamination and the need for secondary bonding, while maintaining lightweight properties and effective thermal protection up to extreme temperatures.

Problems solved by technology

Rockets, missiles and other similar airborne structures that move through the air at very high speeds are subject to harsh environmental conditions during use.

Weight restrictions and cost concerns for such airborne structures, however, limit the feasibility of using materials such as metals and metal alloys.

Further, polymer composites have low densities, so that components fabricated of these materials are of lighter weight and well within applicable weight limits.

Although use of polymer composites for airborne structures can provide many advantages, material properties of such composites may restrict the use of polymer composites alone in high temperature and / or high-pressure applications.

Significantly, polymer composites are not fire resistant, and a thermally resistant material must be used in connection with polymer coating so that the polymer composite does not soften or ignite during use.

Additionally, the strength of the polymer composite alone often is not sufficient to withstand typical forces associated with missile systems and the like.

These post-bonded heat shields are often damaged during handling, and are rendered susceptible to debonding and moisture degradation over time.

As a result, the damaged heat shields typically must be repaired frequently over the life of the component, which is not only inefficient but costly, as well.

Images