Abstract: The invention is a thermal insulation tile for providing thermal protection of the external surface of a vehicle. In detail, the tile includes a rigid ceramic core having top and bottom surfaces, side surfaces and parallel front and rear surfaces at a 15 to 45 degree angle to said top surface. A cover completely surrounds the core and is bonded thereto. A plurality of rigid rods extends through the core and the cover and are bonded thereto. The rods are at an angle of between 10 and 30 degrees to the top surface of the core, with the angle thereof in an angular direction opposite to the front and rear surfaces of the core.

Abstract: The invention is a thermal insulation tile for providing thermal protection of the external surface of a vehicle. In detail, the tile includes a rigid ceramic core having top and bottom surfaces, side surfaces and parallel front and rear surfaces at a 15 to 45 degree angle to said top surface. A cover completely surrounds the core and is bonded thereto. A plurality of rigid rods extends through the core and the cover and are bonded thereto. The rods are at an angle of between 10 and 30 degrees to the top surface of the core, with the angle thereof in an angular direction opposite to the front and rear surfaces of the core.

Abstract: The present invention is embodied in an abrasion resistant ceramic material comprising a porous ceramic material having a surface, and a preceramic polymer infiltrated into the surface wherein the preceramic polymer is converted to a ceramic state.

Abstract: The present invention is embodied in ceramic matrix composites with porous interfacial coatings and the methods and processes for fabricating such coatings integral with the ceramic matrix composites. Each ceramic matrix composite of the present invention includes a fibrous substrate or fabric material with a porous interfacial coating. The coating, prior to processing, is comprised of a coating solution made of a carbon precursor and a ceramic precursor resin dissolved directly within a solvent or solvents. Fabrication is achieved by first desizing the fibrous substrate, second immersing the desized fibrous substrate in the mixed coating solution, third evaporating the solvent and curing the precursor and resin via a low temperature cure, and fourth pyrolyzing the coating via a high temperature pyrolysis, preferably in an inert atmosphere. Next, the coated fibrous substrate is combined with a ceramic matrix composite (CMC).

Abstract: In accordance with the present invention, there is provided a method for adhering a first ceramic foam to a second ceramic foam. The method begins with impregnating a liquid resin with reinforcement fibers to form a liquid reinforced bonding resin. The liquid reinforced bonding resin is then applied to at least one of the ceramic foams. The foams are joined to each other with the liquid reinforced bonding resin disposed therebetween. The liquid reinforced bonding resin is cured to form a solid reinforced bonding resin. The solid reinforced bonding resin is pyrolyzed for adhering the first and second ceramic foams to form a ceramic bonding layer. The ceramic bonding layer is characterized by a porous ceramic matrix with reinforcement fibers disposed therein.

Abstract: The present invention is embodied in a ceramic foam made by mixing a liquid pre-ceramic resin and a liquid phenolic resin, allowing the resultant mixture to chemically foam, curing the mixture for a time and at a temperature sufficiently to convert the mixture to a polymeric foam, and then heating the resultant polymeric foam for a time and at a temperature sufficient to break-down polymers of the polymeric foam and convert the polymeric foam to a ceramic foam. The ceramic foam of the present invention contains residual decomposed components of the liquid phenolic resin and/or liquid pre-ceramic resin.

Abstract: The present invention is a dowel-adhesive method for repairing ceramic matrix composites. The dowel adhesive method embodied in the present invention incorporates both adhesive and mechanical bonding of a patch to a damaged CMC surface area. The damaged area is first identified and then pre-processed. Next, a CMC patch plug is produced and adhesively and mechanically bonded to the pre-processed area. Mechanical bonding is accomplished with dowel pins and corresponding dowel pin holes in the patch plug and the panel. The dowel pins anchor the CMC patch plug to the panel. Adhesive bonding is accomplished by placing a ceramic adhesive between the patch plug and the panel. Also, the dowel pins are adhesively bonded within the dowel pin holes of the plug and the panel. The ceramic adhesive is set by a low temperature cure (if required) and a high temperature firing.

Abstract: In accordance with the present invention, there is provided an abrasion resistant ceramic insulation tile. The insulation tile is provided with a porous ceramic material having a surface. The insulation tile is further provided with a preceramic polymer which is permeated through the surface. The preceramic polymer forms an integral ceramic matrix with the porous ceramic material upon pyrolyzation.

Abstract: The present invention is a low cost carbon fiber-coating produced via a precursor/solvent solution and the methods and processes for fabricating such a carbon fiber-coating. The carbon fiber-coating comprises a fibrous substrate or fabric material and a carbon coating. The carbon coating prior to carbonization, is comprised of a coating solution made of a precursor dissolved directly within a solvent. Fabrication is achieved by first desizing the fibrous substrate, second immersing the desized fibrous substrate in the coating solution, third evaporating the solvent and curing the precursor via a low temperature pyrolysis in preferably an inert atmosphere, and fourth carbonizing the coating via a high temperature pyrolysis. These steps can be repeated as necessary, depending on the desired final thickness of the carbon coating. Multiple applications of the carbon coating can be used to provide limitless final coating thickness.

Abstract: A ceramic composite panel comprising, a pair of skins disposed in spaced relationship to one another and, a ceramic foam disposed between the pair of skins is disclosed. The pair of skin comprises fibers disposed in a pre-ceramic resin in its ceramic state. The foam comprises a cured mixture of a pre-ceramic resin and a phenolic resin.

Abstract: The present invention is a ceramic matrix composite/organic matrix composite hybrid fire shield and the methods and processes for fabricating such a hybrid fire shield. The hybrid fire shield is comprised of an organic matrix composite substrate co-bonded with a cured-ceramic matrix composite layer made of a plurality of cured-ceramic matrix composite plies. First, the surface of the organic matrix composite is appropriately prepared to prevent delamination and enable proper bonding between the surface and the ceramic matrix composite layer. Second, the ceramic matrix composite layer is applied to the surface of the organic matrix composite. Next, the organic matrix composite with the applied ceramic matrix composite layer is processed to produce a co-bonded hybrid structure. The ceramic matrix composite layer is intended to be in direct contact with heat and flames. During impingement of the flames and heat, the cured-CMC layer pyrolyzes and converts from a polymeric to a ceramic composite material.

Abstract: The present invention is embodied in a ceramic matrix composite, comprising a ceramic fiber, a multi-layer coating on the fiber comprising plural alternating layers of an easily-cleaved material and an oxidation resistant material, and a ceramic matrix contacting the coating, the fiber and coating being embedded in the matrix.

Abstract: An apparatus for forming ceramic composite panels is disclosed. The ceramic composite panel comprises a pair of skins disposed in spaced relationship to one another. The pair of skins comprises fibers of a generic fiber system disposed throughout a pre-ceramic resin in its ceramic state. A ceramic foam is disposed between the pair of skins.

Abstract: The present invention is embodied in a method of producing a ceramic foam. The steps for producing the ceramic foam include first mixing a liquid pre-ceramic resin with a liquid phenolic resin, second allowing the resultant mixture to chemically foam, third curing the mixture for a time and at a temperature sufficiently to convert the mixture to a polymeric foam, and then heating the resultant polymeric foam for a time and at a temperature sufficiently to completely break-down polymers of the polymeric foam and convert the polymeric foam to a ceramic foam.