Shell tile thermal protection system

Claim 2

A shell tile adapted for use as a component part of a reusable, externally applied thermal protection system on the skin of aerospace vehicles and the like comprising: upper and lower metallic shells for assuming structural loads, each of said upper and said lower shell having a base and side portions, said metallic shells being constructed from materials able to withstand temperatures of up to approximately 2300° F., said upper shell base being exposed directly to the high temperature environment during vehicle flight; at least one dimpled, lightweight metallic sheet being attached interiorly within said upper shell adjacent the base thereof, thereby adding stiffness and strength to said upper shell; each of said upper and said lower shell having a base and side portions, said lower shell base being attached to the vehicle skin and said upper shell being disposed opposite and joined at the side portion thereof to said lower shell, defining an interior cavity therebetween; insulating means interposed in said interior cavity; and said insulation means including at least one layer of lightweight high temperature insulation inserted into said upper shell and at least one layer of lightweight intermediate temperature insulation inserted into said lower shell.

Claim 3

A shell tile adapted for use as a component part of a reusable, externally applied thermal protection system on the skin of aerospace vehicles and the like comprising: upper and lower metallic shells for assuming structural loads, each of said upper and said lower shell having a base and side portions, said lower shell base being attached to the vehicle skin and said upper shell being disposed opposite and joined at the side portion thereof to said lower shell, defining an interior cavity therebetween; insulating means interposed in said interior cavity; said insulation means including at least one layer of lightweight high temperature insulation inserted into said upper shell and at least one layer of lightweight intermediate temperature insulation inserted into said lower shell; said high temperature insulation comprising a 98.5+% pure silica fiber with a density of 3.5 lb/cu ft; and said intermediate temperature insulation comprising a 98.5+% pure silica fiber with a density of 1.1 lb/cu ft.

Claim 4

A shell tile adapted for use as a component part of a reusable, externally applied thermal protection system on the skin of aerospace vehicles and the like comprising: upper and lower metallic shells for assuming structural loads, each of said upper and said lower shell having a base and side portions, said lower shell base being attached to the vehicle skin and said upper shell being disposed opposite and joined at the side portion thereof to said lower shell, defining an interior cavity therebetween; insulating means interposed in said interior cavity; said insulation means including at least one layer of lightweight high temperature insulation inserted into said upper shell and at least one layer of lightweight intermediate temperature insulation inserted into said lower shell; said high temperature insulation comprising a 98.5+% pure silica fiber with a density of 3.5 lb/cu ft; and said intermediate temperature insulation comprising a 98.5+% pure silica fiber with a density of 1.1 lb/cu ft.

Claim 5

A shell tile adapted for use as a component part of a reusable, externally applied thermal protection system on the skin of aerospace vehicles and the like comprising: upper and lower metallic shells for assuming structural loads, each of said upper and said lower shell having a base and multiple side portions, said lower shell base being attached to the vehicle skin and said upper shell being disposed opposite and joined at the side portion thereof to said lower shell, defining an interior cavity therebetween; insulating means interposed in said interior cavity; said lower shell being telescopically received by said upper shell and including locking means for joining the shell side portions in telescoped connection; said locking means utilizing a self-locking mechanism including at least one upper tapered wedge being attached to the outer surface of at least two sides of said upper shell, at least one lower tapered wedge being attached to the outer surface of an equal number of sides of said lower shell, said upper shell wedges having a flat upper surface and a tapered edge pointing downwards and said lower wedges having a flat lower surface and a tapered edge pointing upwards; said upper and said lower wedges being disposed opposite one another so as to allow said upper wedge to traverse over said lower wedge as downward pressure is applied to said upper shell causing said upper shell sides to spread, until said upper wedge is completely beyond said lower wedge, thereby permitting the flat surfaces thereof to contact for prohibiting reverse movement of said shells due to the inherent spring force exerted thereon by said upper shell sides; restraining means for prohibiting further downward movement of said upper shell once said tapered wedges are locked in place; said restraining means comprising supporting wedges disposed on the outer surface of said sides of said lower shell, thereby impeding further downward movement of said upper shell.

Claim 6

A shell tile adapted for use as a component part of a reusable, externally applied thermal protection system on the skin of aerospace vehicles and the like comprising: upper and lower metallic shells for assuming structural loads, each of said upper and said lower shell having a base and multiple side portions, said lower shell base being attached to the vehicle skin and said upper shell being disposed opposite and joined at the side portion thereof to said lower shell, defining an interior cavity therebetween; insulating means interposed in said interior cavity; said lower shell being telescopically received by said upper shell and including locking means for joining the shell side portions in telescoped connection; said locking means utilizing a self-locking mechanism including at least one upper tapered wedge being attached to the outer surface of at least two sides of said upper shell, at least one lower tapered wedge being attached to the outer surface of an equal number of sides of said lower shell, said upper shell wedges having a flat upper surface and a tapered edge pointing downwards and said lower wedges having a flat lower surface and a tapered edge pointing upwards; said upper and said lower wedges being disposed opposite one another so as to allow said upper wedge to traverse over said lower wedge as downward pressure is applied to said upper shell causing said upper shell sides to spread, until said upper wedge is completely beyond said lower wedge, thereby permitting the flat surfaces thereof to contact for prohibiting reverse movement of said shells due to the inherent spring force exerted thereon by said upper shell sides; restraining means for prohibiting further downward movement of said upper shell once said tapered wedges are locked in place; said restraining means comprising supporting wedges disposed on the outer surface of said sides of said lower shell, thereby impeding further downward movement of said upper shell.

Claim 7

A shell tile adapted for use as a component part of a reusable, externally applied thermal protection system on the skin of aerospace vehicles and the like comprising: upper and lower metallic shells for assuming structural loads, each of said upper and said lower shell having a base and side portions, said lower shell base being attached to the vehicle skin and said upper shell being disposed opposite and joined at the side portion thereof to said lower shell, defining an interior cavity therebetween; insulating means interposed in said interior cavity; connecting means for attaching said lower shell base to the vehicle skin while permitting some relative movement therebetween; said connecting means including a floating nut plate integral with the vehicle skin, and bolting means integral with said lower shell for directly connecting said lower shell to the vehicle skin.

Claim 8

A shell tile adapted for use as a component part of a reusable, externally applied thermal protection system on the skin of aerospace vehicles and the like comprising: upper and lower metallic shells for assuming structural loads, each of said upper and said lower shell having a base and side portions, said lower shell base being attached to the vehicle skin and said upper shell being disposed opposite and joined at the side portion thereof to said lower shell, defining an interior cavity therebetween; insulating means interposed in said interior cavity; connecting means for attaching said lower shell base to the vehicle skin while permitting some relative movement therebetween; said connecting means including a floating nut plate integral with the vehicle skin, and bolting means integral with said lower shell for directly connecting said lower shell to the vehicle skin.

Claim 9

A structure as in claim 4 wherein said floating nut plate comprises: nut means for securing said bolting means in place; retention means for encasing said nut means, said retention means being securely fastened to the inner surface of said skin and constructed so as to permit limited lateral and vertical movement of said nut means, while preventing rotational movement thereof; said retention means also having an apertured portion in its upper surface and a lower surface comprising a retaining lip thereby allowing said bolting means to penetrate and connect to said nut means; and said bolting means being of such diameter as to form a loose fit through said apertured portion and said skin, thereby reducing the strain between said skin and said tile structure by allowing limited lateral movement of the nut-bolt combination during periods of thermal or mechanical expansion.