Method of manufacturing advanced composites and coatings for radiation environment shielding
12051516 ยท 2024-07-30
Assignee
Inventors
Cpc classification
D06M11/82
TEXTILES; PAPER
C08J2463/00
CHEMISTRY; METALLURGY
B32B27/12
PERFORMING OPERATIONS; TRANSPORTING
D06M11/58
TEXTILES; PAPER
G21F3/00
PHYSICS
B32B2307/212
PERFORMING OPERATIONS; TRANSPORTING
B29C70/48
PERFORMING OPERATIONS; TRANSPORTING
B32B2255/02
PERFORMING OPERATIONS; TRANSPORTING
B29K2063/00
PERFORMING OPERATIONS; TRANSPORTING
B29C70/443
PERFORMING OPERATIONS; TRANSPORTING
D06M11/74
TEXTILES; PAPER
B32B2262/106
PERFORMING OPERATIONS; TRANSPORTING
International classification
B29C70/34
PERFORMING OPERATIONS; TRANSPORTING
B29C70/44
PERFORMING OPERATIONS; TRANSPORTING
B29C70/48
PERFORMING OPERATIONS; TRANSPORTING
B32B27/12
PERFORMING OPERATIONS; TRANSPORTING
B32B5/02
PERFORMING OPERATIONS; TRANSPORTING
C08J5/12
CHEMISTRY; METALLURGY
C08J5/24
CHEMISTRY; METALLURGY
D06M11/58
TEXTILES; PAPER
D06M11/74
TEXTILES; PAPER
D06M11/82
TEXTILES; PAPER
Abstract
Radiation shielding performs a range of functions determined by the type and number of layers of materials used, thickness, weight, and structural support afforded by the radiation shielding. A radiation shield laminate stack may be constructed consisting of a plurality of layers of ultra-high molecular weight (UHMW) polyethylene, polyethylene film, and carbon fiber, which is held together with an epoxy. The carbon fiber lay may be coated with nanoparticles of Boron (B) or Boron Nitride (BN), Boron Oxide (B.sub.2O.sub.3) or Boron Carbide (B.sub.4C) or a combination thereof to increase the shielding properties of the laminate stack. The radiation shield is lighter than aluminum, structurally sound, and thus may be used in the space environment to effectively block Galactic Cosmic Rays, atomic oxygen and UV radiation.
Claims
1. A method of manufacturing a radiation shield using vacuum assisted resin transfer molding comprising: forming a layup of materials in a vacuum assisted resin transfer mold comprising: providing a first plurality of layers of polyethylene; providing one or more layers of a carbon fabric with a boron based coating between 25-50 ?m thick; providing a second plurality of layers of polyethylene; sealing the mold and pulling a vacuum on the mold to evacuate all excess atmospheric air; and, infusing the layup with epoxy resin.
2. The method of manufacturing a radiation shield using vacuum assisted resin transfer molding according to claim 1 wherein the carbon fabric has a boron nitride coating.
3. The method of manufacturing a radiation shield using vacuum assisted resin transfer molding according to claim 1 wherein the carbon fabric has a boron carbide coating.
4. The method of manufacturing a radiation shield using vacuum assisted resin transfer molding according to claim 1 wherein the carbon fabric has a boron oxide coating.
5. The method of manufacturing a radiation shield using vacuum assisted resin transfer molding according to claim 1 wherein the carbon fabric has a boron coating.
6. The method of manufacturing a radiation shield using vacuum assisted resin transfer molding according to claim 1 wherein the forming a layup of materials further comprises providing a third plurality of layers of polyethylene between the first plurality of layers of polyethylene and the second plurality of layers of polyethylene.
7. The method of manufacturing a radiation shield using vacuum assisted resin transfer molding according to claim 1 wherein the polyethylene is ultra-high molecular weight polyethylene.
8. The method of manufacturing a radiation shield using vacuum assisted resin transfer molding according to claim 1 wherein the carbon fabric has a boron coating of boron nanoparticles.
9. A method of manufacturing a radiation shield using vacuum assisted resin transfer molding comprising: forming a layup of materials in a vacuum assisted resin transfer mold comprising: providing a first plurality of layers of polyethylene; providing one or more layers of a carbon fabric with a boron based coating between 25-50 ?m thick; providing a second plurality of layers of polyethylene; and, providing a third plurality of layers of polyethylene between the first plurality of layers of polyethylene and the second plurality of layers of polyethylene; sealing the mold and pulling a vacuum on the mold to evacuate all excess atmospheric air; and, infusing the layup with a binder.
10. The method of manufacturing a radiation shield using vacuum assisted resin transfer molding according to claim 9 where in binder is epoxy resin or polyethylene thin film.
11. The method of manufacturing a radiation shield using vacuum assisted resin transfer molding according to claim 9 wherein the based coating is selected from a group consisting of boron, boron nitride, boron oxide, or boron carbide.
12. The method of manufacturing a radiation shield using vacuum assisted resin transfer molding according to claim 9 wherein the carbon fabric has a boron based coating of boron based nanoparticles.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) Certain features of the subject technology are set forth in the appended claims. For purposes of explanation, however, several embodiments of the subject technology are set forth in the following figures.
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
DETAILED DESCRIPTION
(17) The detailed description set forth below is intended as a description of various configurations of the subject technology and is not intended to represent the only configurations in which the subject technology may be practiced. The appended drawings are incorporated herein and constitute a part of the detailed description. The detailed description includes specific details for the purpose of providing a thorough understanding of the subject technology. However, it will be clear and apparent to those skilled in the art that the subject technology is not limited to the specific details set forth herein and may be practiced without these specific details. In some instances, well-known structures and components are shown in block diagram form in order to avoid obscuring the concepts of the subject technology.
(18) Radiation shielding can perform a range of function that is determined by the layer materials used, thickness, weight, and structural supported afforded by the radiation shielding (e.g. space craft, satellites, low earth orbit vehicles, air craft, missiles, personal protection in medical and other settings where radiation is present). However, space, costs, weight, and structural requirements may limit the ability to provide maximum protection in every environment.
(19) Given the diversity of desired applications and functions, it would be beneficial to allow a user to modify components, thicknesses, and functions of a radiation shield to customize the user experience according to the user's desires. Additionally, or alternatively, it would be beneficial to allow a manufacturer to modify components and functions of a radiation shield according to custom orders from a purchaser and/or to streamline a manufacturing process. The radiation shield, including the number and sequence of the composite layers, of the present disclosure facilitate customization, adaptability, and modification by a user according to the user's desires.
(20) The radiation shield of the present disclosure can consist of various layers of material to provide a variety of different functions and characteristics to achieve the results that are desired by a user. The layered composite configuration allows a user to easily customize the composite stack with one or more layers of material. The sequence of the layers and the number of layers in the stack may vary to provide different functions at different times and to achieve the results desired by a user. Accordingly, a radiation shield of the present disclosure need not require the inclusion of a specific layer to provide every function that will later be desired by the user. Instead, the radiation shield, the sequence of layers, and the number of layers can be customized to achieve the results desired by a user.
(21) The radiation shield of the present disclosure can also shield sensitive electrical systems and microcircuits from electromagnetic pulses (EMP). The radiation shield can provide shielding to entire electrical systems, cabling, or as a coating on the cabling.
The Radiation Shield
(22) The radiation shield (100) is a stack consisting of a plurality of layers of ultra-high molecular weight (UHMW) polyethylene or high density polyethylene (110), polyethylene film (115), and carbon fiber (120). The layers of the stack are held together by epoxy or polyethylene film (125) to form a substantially rigid radiation shield (100) capable of providing structural support in its intended application. In the preferred embodiment of the invention the ultra-high molecular weight polyethylene (110) is Spectra? from Bally Ribbon Mills in Bally, Pennsylvania, U.S.A. The carbon fiber (120) layer may consist of carbon fiber fabric or carbon fiber fabric that has been coated with nanoparticles of Boron (B) or Boron Nitride (BN). In an alternative preferred embodiment the carbon fiber (120) layer is coated with Boron Oxide (B.sub.2O.sub.3) or Boron Carbide (B.sub.4C).
(23) In the preferred embodiment of the invention the radiation shield stack has a top layer of UHMW polyethylene (110a) and a bottom layer of UHMW polyethylene (110b). Preferably, a polyethylene film (120) is placed in the stack immediately adjacent to the UHWM polyethylene layer (110) to promote improved bonding between the UHMW polyethylene layer (110) and the carbon fiber layers (120).
Coating the Carbon Fiber Fabric Layers
(24) The carbon fiber (120) layer may consist of carbon fiber fabric or carbon fiber fabric that has been coated with nanoparticles of Boron (B) or Boron Nitride (BN). In an alternative preferred embodiment the carbon fiber (120) layer is coated with Boron Oxide (B.sub.2O.sub.3), Boron Carbide (B.sub.4C). A plasma treatment is used to coat the carbon fiber (120) layer with Boron (B), Boron Nitride (BN), Boron Carbide (B.sub.4C) powder, or a blend of these powders. The coating of the carbon fiber (120) layer improves bonding of the epoxy or polyethylene thin file (110) with the carbon fiber (120) layer due to changes of the carbon fiber fabric (120) surface roughness, which improves wettability of the epoxy or polyethylene thin film (110) with the carbon fiber (120) layer during fabrication of the radiation shield (110).
(25) The preferred method of coating the carbon fiber (120) layer with Boron (B), Boron Nitride (BN), Boron Oxide (BO), Boron Carbide (B.sub.4C) powder, or a blend of these powders is vapor plasma spray (VPS). The carbon fiber (120) layer may also be coated with heavy metals such as Tungsten, Tantalum, Niobium or a combination of these heavy metals or the Boron based powders. The VPS coating technique involves spraying vaporized molten or vaporized particles onto a substrate, such as the carbon fiber (120) material, for producing a coating. A primary advantage of VPS processing is its high operating temperature of greater than 10,000 K, which is sufficient for melting or vaporization of most feedstock materials. In addition, the highly reactive plasmas can be used to synthesize advanced materials and structures such as nanoparticles and nanotubes.
(26)
(27) In one preferred embodiment Boron (B) feedstock powder is used to coat a carbon fiber (120) layer with a coating thickness ranging between 10 and 75 ?m, and more preferably still ranging between 25-50 ?m. In another preferred embodiment the carbon fiber (120) layer is shown after receiving a BN plasma coating in
(28) A stainless steel frame assembly (300) is preferred to hold the carbon fiber (120) layer in proximity to the nozzle (210,220) during the VPS process.
(29) The advantages of the VPS process for producing the boron-based materials on the carbon fiber (120) layer include: the high temperature plasma enables the processing of high melting temperature materials such as carbides and nitrides to coat the carbon fiber (120) layer; the synthesis of non-congruently melting materials such as BN; manipulation of the density and chemistry of a deposit by varying the process parameters; high processing temperatures and rapid cooling rate allow the retention of fine grained microstructures as well as the fabrication of nano-particles/structures; and high deposition rate (cm/hr).
Anticipated Uses
(30) The present invention is directed to structural radiation shielding for the protection of humans and electronics in aerospace transportation vehicles, space transportation vehicles, large space structures, such as space stations, orbiters, landing vehicles, rovers, habitats and nuclear propulsion. One of ordinary skill in the art would recognize that the present invention may be used in other commercial applications such as providing radiation shielding for particle accelerators, nuclear reactors, radioactive waste containment, satellite hardware, high-altitude airliners, and medical patient shielding. The present invention may also be utilized to provide electromagnetic pulse protection, protection for sensors for neutron detection, and in the field of advanced nanoscale ceramic particles and tubes for composite reinforcement. One of ordinary skill in the art would understand that the number and sequence of layers of the stack consisting of (UHMW) polyethylene (110), a polyethylene film (120), and a carbon fiber (120) layer would have to be adjusted for each such application.
Manufacturing the Radiation Shield
(31) The radiation shield (100) is a stack consisting of a plurality of layers of ultra-high molecular weight (UHMW) polyethylene (110), polyethylene film (115), and carbon fiber (120). The layers of the stack are held together by epoxy to form a substantially rigid radiation shield capable of providing structural support in its intended application. In the preferred embodiment of the invention the ultra-high molecular weight polyethylene is Spectra? from Bally Ribbon Mills in Bally, Pennsylvania, U.S.A. The carbon fiber (120) layer may consist of carbon fiber fabric or carbon fiber fabric that has been coated with nanoparticles of Boron (B) or Boron Nitride (BN). In an alternative preferred embodiment the carbon fiber (120) layer is coated with Boron Oxide (B.sub.2O.sub.3), Boron Carbide (B.sub.4C).
(32) The preferred manufacturing method of the radiation shield (100) is a vacuum assisted resin transfer molding (VARTM) procedure.
(33) Following VARTM manufacturing procedures the panel stack is infused from the top center. Vacuum lines are placed around the periphery of the panel to ensure that the vacuum pressure is held throughout the panel. The layup is then bagged and evacuated. Evacuation may be applied for 1 hour to remove excess air from the panel stack before infusion occurs. The panel stack is then infused with one or more of the following: epoxy resin, polyethylene (UHMWPE), low density polyethylene (LDPE), high-density polyethylene (HDPE).
(34) For example the VARTM method was used to fabricate a ? thick composite. For that thickness 12 pieces of UHMW polyethylene and 3 pieces of C fabric coated with BN were utilized. Taking into account the thickness of the BN coating the composition of the proposed composite in weight percentage was estimated to be 43.7% CH2, 27.8% C, 21.8% Epoxy, and 6.7% BN with an elemental composition of C.sub.6.47H.sub.7.49Cl.sub.0.05O.sub.0.25B.sub.0.26N.sub.0.26.
(35) In an alternative preferred manufacturing method additive manufacturing may be used to make the radiation shield (100). Additive manufacturing allows for the creation of intricately shaped materials and materials of varying thicknesses.
Test Results
(36) The effectiveness of the radiation shield (100) to block GCR ions compared to Aluminum using radiation transport calculations. The simulation results shown in
(37) Radiation shield (100), as reflected by samples A and B in the simulation, demonstrate advantages of subject invention composite due to the high hydrogen content of the material and the addition of boron based materials, both of which reduce the contribution of the dose from neutrons created by GCR interactions in shielding.
(38) Test were performed to demonstrate effective shielding against neutrons using radiation shield (100) sample B and a Plutonium-Beryllium (PuBe) neutron source. Table 1 shows the experimentally measured total dose attenuation as a function composite areal density or thickness. For example, 36% of the dose for neutron energies between 2 and 10 MeV were attenuated for an areal density of 5.2 g/cm.sup.2. At an areal density of 18.2 g/cm.sup.2, the total dose attenuation increased to 62%.
(39) Table 1. Total dose attenuation for all deposited energies above 2 MeV at the given shielding thicknesses for composite B.
(40) TABLE-US-00001 Composite areal Total dose density attenuation 5.2 g/cm.sup.2 0.36 10.4 g/cm.sup.2 0.53 15.5 g/cm.sup.2 0.60 18.2 g/cm.sup.2 0.62
(41) Electromagnetic Pulses (EMP) is an instantaneous energy field set off by a high altitude nuclear explosion enabled by missile flight or from a satellite. In addition, x-rays and gamma rays are other components of the EMP spectrum. A widespread EMP effect would lead to long-term disruption of the nation's critical communication, transportation, and military infrastructure. NASA and US military in-space assets are also vulnerable to the effects of EMP. The current state of the art to protect against an EMP attack is the deployment of massive shielding such as a Faraday Cage, concrete structures, and buried cables.
(42) The radiation shield (100), with one or more EMP resistant coatings of high-atomic number (Z) can shield advanced avionics in NASA and US military space assets ranging from satellites to space transportation systems. The thickness needed for EMP resistant coatings with a high atomic number (Z) coating to reduce x-ray flux to 1/100 of its incident value for typical x-ray energies between 10-20 keV were calculated. These results are shown in Table 2. For the highest x-ray energy of 20 KeV, only a coating thickness of 41 micron would suffice to reduce the dose by a factor of 100.
(43) Table 2. Thicknesses needed to reduce x-ray fluences at the given energies to 1/100 of their incident fluence.
(44) TABLE-US-00002 Coating Thickness Energy (keV) (microns) 10 29 11 13 12 12 13 13 14 15 15 18 16 22 17 25 18 30 19 35 20 41
Closing
(45) Accordingly, embodiments of the present disclosure provide a radiation shield that provide a variety of different components and functions to achieve the results that are desired by a user. The configurations allow a user to easily customize the radiation shield with one or more functional configurations of the composite layers or coatings provided to obtain the desired features. Accordingly, a radiation shield of the present disclosure need not include a specific number of layers in a specific sequence. Instead, the radiation shield can have any number of layers or coatings as customizable by the use to achieve the desired results.
(46) A reference to an element in the singular is not intended to mean one and only one unless specifically so stated, but rather one or more. For example, a layer may refer to one or more layers. An element proceeded by a, an,, the, or said does not, without further constraints, preclude the existence of additional same elements.
(47) Headings and subheadings, if any, are used for convenience only and do not limit the invention. The word exemplary is used to mean serving as an example or illustration. To the extent that the term include, have, or the like is used, such term is intended to be inclusive in a manner similar to the term comprise as comprise is interpreted when employed as a transitional word in a claim. Relational terms such as first and second and the like may be used to distinguish one entity or action from another without necessarily requiring or implying any actual such relationship or order between such entities or action.
(48) Phrases such as an aspect, the aspect, another aspect, some aspects, one or more aspects, an implementation, the implementation, another implementation, some implementations, one or more implementations, an embodiment, the embodiment, another embodiment, some embodiments, one or more embodiments, a configuration, the configuration, another configuration, some configurations, one or more configurations, the subject technology, the disclosure, the present disclosure, other variations thereof and alike are for convenience and do not imply that a disclosure relating to such phrase(s) is essential to the subject technology or that such disclosure applies to all configurations of the subject technology. A disclosure relating to such phrase(s) may apply to all configurations, or one or more configurations. A disclosure relating to such phrase(s) may provide one or more examples. A phrase such as an aspect or some aspects may refer to one or more aspects and vice versa, and this applies similarly to other foregoing phrases.
(49) A phrase at least one of preceding a series of items, with the terms and or or to separate any of the items, modifies the list as a whole, rather than each member of the list. The phrase at least one of does not require selection of at least one item; rather, the phrase allows a meaning that includes at least one of any one of the items, and/or at least one of any combination of the items, and/or at least one of each of the items. By way of example, each of the phrases at least one of A, B, and C or at least one of A, B, or C refers to only A, only B, or only C; any combination of A, B, and C; and/or at least one of each of A, B, and C.
(50) It is understood that the specific order or hierarchy of steps, operations, or processes disclosed is an illustration of exemplary approaches. Unless explicitly stated otherwise, it is understood that the specific order or hierarchy of steps, operations, or processes may be performed in different order. Some of the steps, operations, or processes may be performed simultaneously. The accompanying method claims, if any, present elements of the various steps, operations or processes in a sample order, and are not meant to be limited to the specific order or hierarchy presented. These may be performed in serial, linearly, in parallel or in different order. It should be understood that the described instructions, operations, and systems can generally be integrated together in a single product or multiple products. Terms such as top, bottom, front, rear, side, horizontal, vertical, and the like refer to an arbitrary frame of reference, rather than to the ordinary gravitational frame of reference. Thus, such a term may extend upwardly, downwardly, diagonally, or horizontally in a gravitational frame of reference.
(51) The disclosure is provided to enable any person skilled in the art to practice the various aspects described herein. In some instances, well-known structures and components are shown in block diagram form in order to avoid obscuring the concepts of the subject technology. The disclosure provides various examples of the subject technology, and the subject technology is not limited to these examples. Various modifications to these aspects will be readily apparent to those skilled in the art, and the principles described herein may be applied to other aspects.
(52) All structural and functional equivalents to the elements of the various aspects described throughout the disclosure that are known or later come to be known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the claims. Moreover, nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure is explicitly recited in the claims. No claim element is to be construed under the provisions of 35 U.S.C. ? 112(f), unless the element is expressly recited using the phrase means for or, in the case of a method claim, the element is recited using the phrase step for.
(53) The title, background, brief description of the drawings, abstract, and drawings are hereby incorporated into the disclosure and are provided as illustrative examples of the disclosure, not as restrictive descriptions. It is submitted with the understanding that they will not be used to limit the scope or meaning of the claims. In addition, in the detailed description, it can be seen that the description provides illustrative examples and the various features are grouped together in various implementations for the purpose of streamlining the disclosure. The method of disclosure is not to be interpreted as reflecting an intention that the claimed subject matter requires more features than are expressly recited in each claim. Rather, as the claims reflect, inventive subject matter lies in less than all features of a single disclosed configuration or operation. The claims are hereby incorporated into the detailed description, with each claim standing on its own as a separately claimed subject matter.
(54) The claims are not intended to be limited to the aspects described herein, but are to be accorded the full scope consistent with the language of the claims and to encompass all legal equivalents. Notwithstanding, none of the claims are intended to embrace subject matter that fails to satisfy the requirements of the applicable patent law, nor should they be interpreted in such a way.