Multi-functional composite structure for extreme environments
10442559 ยท 2019-10-15
Assignee
Inventors
Cpc classification
E04C2/521
FIXED CONSTRUCTIONS
B32B2571/02
PERFORMING OPERATIONS; TRANSPORTING
B64D2221/00
PERFORMING OPERATIONS; TRANSPORTING
B32B27/12
PERFORMING OPERATIONS; TRANSPORTING
B64G1/56
PERFORMING OPERATIONS; TRANSPORTING
B32B2307/212
PERFORMING OPERATIONS; TRANSPORTING
B32B9/007
PERFORMING OPERATIONS; TRANSPORTING
B32B2262/14
PERFORMING OPERATIONS; TRANSPORTING
B32B3/08
PERFORMING OPERATIONS; TRANSPORTING
B64C1/12
PERFORMING OPERATIONS; TRANSPORTING
B32B7/12
PERFORMING OPERATIONS; TRANSPORTING
E04C2/284
FIXED CONSTRUCTIONS
B64G1/10
PERFORMING OPERATIONS; TRANSPORTING
E04B1/92
FIXED CONSTRUCTIONS
B32B5/02
PERFORMING OPERATIONS; TRANSPORTING
B32B2262/106
PERFORMING OPERATIONS; TRANSPORTING
B32B15/02
PERFORMING OPERATIONS; TRANSPORTING
E04B2001/925
FIXED CONSTRUCTIONS
Y02T50/40
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
E04C2/526
FIXED CONSTRUCTIONS
B32B2250/40
PERFORMING OPERATIONS; TRANSPORTING
B64C1/406
PERFORMING OPERATIONS; TRANSPORTING
B32B3/12
PERFORMING OPERATIONS; TRANSPORTING
International classification
E04C2/52
FIXED CONSTRUCTIONS
B32B5/02
PERFORMING OPERATIONS; TRANSPORTING
B64C1/06
PERFORMING OPERATIONS; TRANSPORTING
B64C1/12
PERFORMING OPERATIONS; TRANSPORTING
B64C1/40
PERFORMING OPERATIONS; TRANSPORTING
B32B3/08
PERFORMING OPERATIONS; TRANSPORTING
B64G1/56
PERFORMING OPERATIONS; TRANSPORTING
E04B1/92
FIXED CONSTRUCTIONS
E04C2/284
FIXED CONSTRUCTIONS
E04C2/34
FIXED CONSTRUCTIONS
B32B27/12
PERFORMING OPERATIONS; TRANSPORTING
B32B27/06
PERFORMING OPERATIONS; TRANSPORTING
B32B15/02
PERFORMING OPERATIONS; TRANSPORTING
B32B9/00
PERFORMING OPERATIONS; TRANSPORTING
B32B7/12
PERFORMING OPERATIONS; TRANSPORTING
B32B3/12
PERFORMING OPERATIONS; TRANSPORTING
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.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DESCRIPTION
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(15) The composite structure 10 is constructed according to the method represented in
(16) The outer panel 12 is constructed of composite materials. The composite materials of the outer panel 12 are selected from a group comprising Kevlar 49, fiberglass, boron carbide, Spectra Fiber, Nextel fabric, graphite/epoxy fabric, spectra fiber/high density polyethylene (HDPE), graphite/epoxy tape, or other equivalent materials or combinations of equivalent materials such as graphite/spectra/high density polyethylene laminate.
(17) The types of composite materials and the combination of composite materials that go into the construction of the outer panel 12 are dependent on the characteristics of the extreme environment to which the outer panel 12 is exposed. Examples of possible composite materials are shown in the following table listing composite materials, their hydrogen contents by percentage and their material index with materials having larger index numbers providing better radiation protection.
(18) TABLE-US-00001 Materials index Hydrogen (the bigger number, Contents the better radiation Shield material (%) protection) Polyethylene/Spectra Fiber (Laminate) 25 25 Polyethylene Fiber (Dry Fiber) 25 25 Spectra Fiber/Epoxy (Laminate) 20 20 Kevlar 49/Polyester Fabric (Laminate) 18.5 18 PolyMethacrylImide (PMI) Foam 16 16 Crosslinked Polyethylene Foam 14.4 14 Kevlar 49/Epoxy (Laminate) 13.5 13 Graphite/Polyethylene 12.5 12.5 Aramid Fiber(Dry Fiber) 12.1 12 Polyisocyanurate Foam 12.1 12 Graphite/Epoxy Tape (Laminate) 7.5 7 Graphite/Epoxy Fabric (Laminate) 7.5 7 Boron/Epoxy Laminate (Laminate) 7.5 7 Polyurethane Foam 4.1 4 Polyisocyanurate Foam 4.1 4
(19) There are potentially many combinations of the materials listed in the table that can be used to form the outer panel 12. One possible combination of composite materials is represented in
(20) The composite materials of the outer panel 12 are chosen to primarily prevent the penetration or damage of an inner panel 24 on the opposite side of the composite structure 10. The outer panel 12 is designed to absorb most of the energy out of a micro-meteoroid and orbital debris (MMOD) projectile impact with the composite structure 10 and vaporize the MMOD projectile. The outer panel 12 is designed to withstand impacts of MMOD projectiles having diameter dimensions up to 1 cm and speeds varying from 3 km/s to 30 km/s.
(21) The hydrogen content of the composite material chosen to construct the outer panel 12 will also provide extra radiation protection as well as additional thermal insulation and will also increase the structural loads that can be supported by the outer panel 12.
(22) The inner panel 24 of the composite structure 10 is constructed to primarily provide a sealed and temperature/humidity controlled environment inside the composite structure. The inner panel 24 has a thickness between an exterior surface 26 and an interior surface 28 of the inner panel. The thickness of the inner panel 24 can be in a range of 0.2 cm to 0.4 cm or more, for example 0.2 cm to 2.0 cm depending on the type of environment the inner panel 24 is exposed to. The exterior surface 26 of the inner panel 24 and the interior surface 28 of the inner panel 24 are smooth, continuous surfaces. As represented in
(23) The inner panel 24 is constructed of composite materials such as those listed in the above table. The composite materials of the inner panel 24 are selected from a group comprising Kevlar 49, fiberglass, boron carbide, Spectra Fiber, Nextel fabric, graphite/epoxy fabric, spectra fiber/high density polyethylene (HDPE), graphite/epoxy tape, or other equivalent materials or combinations of equivalent materials such as graphite/spectra/high density polyethylene laminate.
(24) There are potentially many combinations of the materials listed in the above table that can be used to form the inner panel 24. One possible combination of composite materials is represented in
(25) The composite materials of the inner panel 24 are chosen so that the inner panel 24 provides a sealed and temperature/humidity controlled environment for humans or animals and/or sensitive equipment and instruments.
(26) The hydrogen content of the composite material chosen to construct the inner panel 24 will also provide extra radiation protection as well as additional thermal insulation and will also increase the structural loads than can be supported by the inner panel 24.
(27) As represented in
(28) A standoff or support structure 44 is positioned in the space 42. The support structure 44 is connected to the interior surface 16 of the outer panel 12 and the interior surface 28 of the inner panel 24. The support structure 44 has a lattice configuration comprised of a plurality of walls 46 that are connected to the interior surface 16 of the outer panel 12 and the interior surface 28 of the inner panel 24. The plurality of walls 46 surround a plurality of divided spaces 48 between the interior surface 16 of the outer panel 12 and the interior surface 28 of the inner panel 24 with the plurality of walls 46 separating the plurality of divided spaces 48. In the representation of the composite structure 10 in
(29) Referring to
(30) As stated above, the configuration of the support structure 44 of the composite structure 10 can be other than the trapezoidal configuration described. Referring to
(31) The construction of the composite structure 10 represented in
(32) Returning to the composite structure 10 of
(33) A wire 66 is extended through the space 42. The wire 66 passes through the space 42 between the interior surface 16 of the outer panel 12 and the interior surface 28 of the inner panel 24. The wire 66 could have a cross-section configuration of a conventional wire, or could have a cross-section configuration of a strip or other equivalent cross-section configuration. The wire 66 could be a plurality of wires. The wire 66 has high electrical conductivity and could be a super conductor. As represented in
(34) Insulation 72 is also provided in the space 42 between the interior surface 16 of the outer panel 12 and the interior surface 28 of the inner panel 24. The insulation 72 is multi-layer insulation. As represented in
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(36) The method of
(37) Referring to
(38) The wire 66 provides a method of shielding a spacecraft 74 constructed with the composite structure 10 as described above with reference to
(39) The method of
(40) In applications of the composite structure 10, where additional strength and protection is required, multiple layers of the composite structure 10 may be employed.
(41) As various modifications could be made in the construction of the apparatus and its method of operation herein described and illustrated without departing from the scope of the invention, it is intended that all matter contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative rather than limiting. Thus, the breadth and scope of the present disclosure should not be limited by any of the above described exemplary embodiments, but should be defined only in accordance with the following claims appended hereto and their equivalents.