Abstract: Ceramic insulation has a mat of intersecting, discrete ceramic fibers bonded with a sol-gel glass binder. A fabric-reinforced glass coating is bonded to at least one surface of the mat. The insulation is prepared by forming a slurry of ceramic fibers, molding the slurry to form a soft felt mat, drying the mat, and incrementally introducing the binder into the mat with a multiple-impregnation technique, which controls shrinkage of the ceramic fiber mat. The fabric-reinforced glass coating is formed by applying a glass fiber cloth to a surface of the ceramic fiber mat and coating the same with a powdered glass. The powdered glass is melted and cooled.The process provides a layering technique that permits formation of a continuous fibrous structure having layers that impart distinct characteristics at desired regions within the structure.

Abstract: A method for making a thermal insulating structure for providing thermal insulation, structural load accommodation, and noise attenuation for surfaces in aerospace systems that are exposed to high temperatures is disclosed. Structure to be protected is a high-temperature solid back sheet to which is a honeycomb core having a perforated buried septum is bonded to a substrate. A layer of cast fiber-ceramic insulation is secured to the honeycomb core, filling portions of the core outward from the septum and extending beyond the outer face of the core. To absorb structural loads, a densified top coat overlies the insulating layer. To minimize the transmission of shear-inducing loads into the insulating layer, the outer face of the honeycomb core has an irregular surface. Core cell vents extending through the walls of adjacent cells provide a controlled airspace between the back sheet and the buried septum through which a fluid coolant may be circulated.

Abstract: A thermal insulating structure for providing thermal insulation, structural load accommodations, and noise attenuation for surfaces in aerospace systems that are exposed to high temperatures. At the side adjacent the structure to be protected is a high-temperature solid back sheet to which is adhesively bonded a honeycomb core having a perforated buried septum. A layer of cast fiber-ceramic insulation is secured to the honeycomb core, filling portions of the core outward from the septum and extending beyond the outer face of the core. To absorb structural loads, a densified top coat overlies the insulating layer. To minimize the transmission of shear-inducing loads into the insulating layer, the outer face of the honeycomb core has an irregular surface. Core cell vents extending through the walls of adjacent cells provide a controlled airspace between the back sheet and the buried septum through which a fluid coolant may be circulated.

Abstract: Freestanding glass reinforced ceramic protective coatings are made with a shrinkable silica preform technique. The coatings may be bonded to heat sensitive organic (plastic) or inorganic (ceramic or metal) substrates to provide thermal and impact protection.

Abstract: A gelled film can be deposited directly on a sensitive substrate to obtain a protective ceramic coating on the substrate. An alumina sol, for example, can be sprayed through a flowing stream of ammonia to create a uniformly thick film, which adheres to metals, plastics, or, in some cases, water soluble materials. This film can then be cured, usually at low firing temperatures, to complete the coating.