Multi-functional composite structure for extreme environments

Patent metadata

Field	Value
Publication number	US-10442559-B2
Application number	US-201615226219-A
Country	US
Kind code	B2
Filing date	Aug 2, 2016
Priority date	Aug 2, 2016
Publication date	Oct 15, 2019
Grant date	Oct 15, 2019

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.

First claim

What is claimed:

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 fa

Assignees

• Boeing Co

Inventors

• Dong Jian
• Hussain Naveed Moayyed

Classifications

• B64G1/10

  Artificial satellites; Systems of such satellites; Interplanetary vehicles (space shuttles B64G1/14) · CPC title

• B32B5/02

  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 title

• H05K9/0007

  Casings (standardised racks H05K9/0062) · CPC title

• B32B2262/0269

  Aromatic polyamide fibres · CPC title

• B64C1/066

  Interior liners · CPC title