HEAT ABSORBING SURFACE COATING

Abstract: A heat absorbing coating having a plurality of micro-capsules each being an encapsulant shell and a heat absorbing material within the shell, and a carrier adherable to a substrate and throughout which the micro-capsules are dispersed. The heat absorbing material is preferably a phase change material and can be non-limitedly chosen from the group consisting of polyethylene, polypropylene, polywax, and combinations thereof. Shell material can be a metal such as copper, for example, or a polymer. The carrier can be a sprayable polymer mix which provides significant efficacy in uniform application to a substrate. An inventive substrate structure, such as an aircraft structure for example, has thereon the above-defined coating in an amount sufficient to absorb a sufficient amount of heat from the substrate to substantially inhibit thermal erosion in normal operating environments.

Description: HEAT ABSORBING SURFACE COATING Field of the Invention The present invention relates in general to protective coatings, and in particular to a heat absorbing coating comprising micro-encapsulated heat absorbing material such as phase change material dispersed throughout a carrier, and additionally includes a substrate having such a coating and methodology for thermally protecting a substrate. Background of the Invention Certain substrates that are subjected to environments that produce heat in the substrates can have significantly reduced lifetimes because they do not possess sufficient durability to withstand thermal erosion. One example of a group of such substrates is found in aircraft structures. Specifically, most modern jet aircraft structures require the use of advanced materials that achieve product cost effectiveness. However, because of the high-speed environment in which these structures operate and the attendant heat generated therefrom, thermal erosion durability of the structures, and especially highly vulnerable portions thereof such as leading edges and engine exhaust nozzles, is reduced to considerably less than desirable for efficient and economical operations. The use of micro-encapsulated thermal absorbing material has been taught, for example, for temperature control by incorporation in potting materials, slurries, building structures such as concrete and gypsum board, solar collecting structures, and alloys used in solar- steam systems. Disclosed thermal absorbing material includes phase change materials, while disclosed encapsulant materials include metals and polymers. However, none of these prior-art applications provides or suggests any structural treatment beyond incorporation of encapsulated thermal-absorbing material within the structure. Consequently, thermal erosion of the surface of a substrate is not addressed. In view of the potential for thermal degradation of structural surfaces exposed to significant heat, it is apparent that a need is present for a surface coating that can function to thermally manage environmentally produced heat erosion at the sites of damage. It is therefore a primary object of the present invention to provide a heat absorbing surface coating including a micro-encapsulated heat absorbing material dispersed in a carrier medium for application to a substrate. Another object of the present invention is to provide a heat absorbing surface coating wherein the carrier medium is a sprayable polymer matrix. Yet another object of the present invention is to provide a substrate having a heat absorbing surface coating thereon comprising a micro-encapsulated phase change material dispersed in a carrier medium for application to a substrate. Still another object of the present invention is to provide methodology for thermally protecting a substrate comprising the application on the substrate of a heat absorbing surface coating including a micro-encapsulated heat absorbing material dispersed in a carrier medium. These and other objects of the present invention will become apparent throughout the description which now follows. Summary of the Invention The present invention is a heat absorbing coating comprising a plurality of micro-capsules each comprising an encapsulant shell and a heat absorbing material within the shell, and a carrier adherable to a substrate and throughout which the micro-capsules are dispersed. The heat absorbing material is preferably a phase change material and can be non-li itedly chosen from the group consisting of polyethylene, polypropylene, polywax, and combinations thereof which may have a melting point between about 425 °F and about 475 °F. Shell material can be a metal such as copper, for example, or a polymer. The carrier can be a sprayable polymer mix which provides significant efficacy in uniform application to a substrate. The present invention includes a substrate having thereon the above inventive coating, with the substrate exemplified by an aircraft structure, such as, for example, a leading edge or an engine exhaust nozzle, that experiences extreme heat in its operating environment. A structure so coated is significantly protected from thermal erosion, with methodology accomplishing such protection comprising the application of the above described coating onto a substrate in an amount sufficient to absorb a sufficient amount of heat and thereby prevent or significantly inhibit thermal degradation. Brief Description of the Drawings An illustrative and presently preferred embodiment of the invention is shown in the accompanying drawings in which: Figure 1 is a side elevation graphic representation of a carrier material adhered to a surface of a structure and having dispersed within the carrier material a plurality of micro-capsules each comprising an encapsulant shell and a phase change material within the shell; and Figure 2 is a cross sectional view of one micro- capsule of Figure 1. Detailed Description of the Preferred Embodiment Referring to Figure 1, a structure 10, here being representative of a wing of an aircraft, is shown with a heat absorbing coating 12 adhered thereon. The coating 12 is comprised of a carrier 20 and a plurality of conventional micro-capsules 14, with each micro-capsule constructed of an encapsulant shell 16 and a phase change material 18 within the shell 16 as illustrated in Figure 2. The carrier 20 here shown is a polymer matrix commercially available under the name PR1991 manufactured by Courtaulds Aerospace, Glendale, California. The micro-capsules are manufactured by Providence Metallurgy, Pautucket, Rhode Island. These micro-capsules have a copper shell within which is housed polypropylene manufactured by Hoechst, Summit, New Jersey. This polypropylene is a phase change material having a melting point of about 433 °F and an energy absorption value at its heat of fusion of 24 calories per gram. For applications to aircraft structures, a melting point of phase change material between about 425 °F and about 475 °F is preferred as being relevant to thermal capacities generally required at, for example, leading edges and jet engine exhaust nozzles. Various polymers or metals may be used as the phase change material depending upon the design requirements and the temperature limits of the structure being coated. It is to be understood, however, that the heat absorbing material within the micro- capsules of the coating comprising the present invention is preferably, but not limited to, phase change material. Likewise, the shell can be constructed of a metal or polymer having adequate heat transfer properties, and capable of restraining the phase change material 18 from diffusing into the carrier 20 during thermal cycling, all as would be recognized by a person with ordinary skill in the art. Typical, but not limiting, dimensions of the micro-capsules include a shell thickness of from about lμ to about 10// and a diameter of from about 25μ to about 200μ. The particle sizes are sufficiently small so as to pass through a conventional paint spray gun. The coating 12 is prepared by mixing the micro- capsules 14 with the carrier 20. This mixing occurs simultaneously with spray coating the substrate. A conventional paint spray gun with a rotating agitator cup is used to spray the coating. While the amount of coating determines thermal capacity thereof, a concentration of .003 pounds/square foot of phase change material will reduce surface temperature by 50 °F. While an illustrative and presently preferred embodiment of the invention has been described in detail herein, it is to be understood that the inventive concepts may be otherwise variously embodied and employed and that the appended claims are intended to be construed to include such variations except insofar as limited by the prior art. WHAT IS CLAIMED IS: 1. A heat absorbing coating comprising: a) a plurality of micro-capsules each comprising an encapsulant shell and a heat absorbing material within said shell; and b) a carrier for transporting the micro capsules, said carrier being adherable to a substrate and throughout which the micro-capsules are dispersed. 2. A heat absorbing coating as claimed in Claim 1 wherein the heat absorbing material is a phase change material . 3. A heat absorbing coating as claimed in Claim 2 wherein the phase change material is chosen from the group consisting of polyethylene, polypropylene, polywax and combinations thereof. 4. A heat absorbing coating as claimed in Claim 2 wherein the phase change material has a melting point between about 425 °F and about 475 °F. 5. A heat absorbing coating as claimed in Claim 2 wherein the shell is constructed of a metal or a polymer. 6. A heat absorbing coating as claimed in Claim 5 wherein the shell is constructed of copper. 7. A heat absorbing coating as claimed in Claim 2 wherein the shell has a thickness of from about Iμ to about lOμ. 8. A heat absorbing coating as claimed in Claim 2 wherein each micro-capsule has a diameter of from about 25 to about 200μ. 9. A heat absorbing coating as claimed in Claim 2 wherein the carrier is a sprayable polymer matrix. 10. A coated substrate having thereon a heat absorbing coating, the coating comprising: a) a substrate surface; b) a heat absorbing coating on the substrate surface, said coating comprising a plurality of micro-capsules each comprising an encapsulant shell and a heat absorbing material within said shell; and c) a carrier for transporting the micro capsules, said carrier being adherable to a substrate surface and throughout which the micro- capsules are substantially homogeneously dispersed. 11. A substrate as claimed in Claim 10 wherein in the coating the heat absorbing material is a phase change material . 12. A substrate as claimed in Claim 11 wherein said substrate surface is a structure of an aircraft. 13. A substrate as claimed in Claim 12 wherein the structure is a leading edge of the aircraft. 14. A substrate as claimed in Claim 12 wherein the structure is an engine exhaust nozzle of the aircraft. 15. A substrate as claimed in Claim 11 wherein the phase change material is chosen from the group consisting of polyethylene, polypropylene, polywax and combinations thereof. 16. A substrate as claimed in Claim 11 wherein the phase change material has a melting point between about 425°F and about 475°F. 17. A substrate as claimed in Claim 11 wherein the shell is constructed of a metal or a polymer. 18. A substrate as claimed in Claim 17 wherein the shell is constructed of copper. 19. A substrate as claimed in Claim 11 wherein the shell has a thickness of from about Iμ to about lOμ. 20. A substrate as claimed in Claim 11 wherein each micro-capsule has a diameter of from about 25μ to about 200 . 21. A substrate as claimed in Claim 11 wherein the carrier is a sprayable polymer matrix. 22. A method of protecting a substrate from thermal erosion, the method comprising applying a heat absorbing coating onto the substrate in an amount sufficient to absorb a sufficient amount of heat from the substrate to substantially inhibit thermal erosion, said coating comprising a plurality of micro-capsules each comprising an encapsulant shell and a heat absorbing material within said shell, and a carrier adherable to the substrate for transporting the micro capsules and throughout which the micro-capsules are dispersed. 23. A method as claimed in Claim 22 wherein in the heat absorbing coating the heat absorbing material is a phase change material . 24. A method as claimed in Claim 23 wherein the substrate is a structure of an aircraft. 25. A method as claimed in Claim 24 wherein the structure is a leading edge of the aircraft. 26. A method as claimed in Claim 24 wherein the structure is an engine exhaust nozzle of the aircraft. 27. A method as claimed in Claim 23 wherein in the heat absorbing coating the phase change material is chosen from the group consisting of polyethylene, polypropylene, polywax and combinations thereof. 28. A method as claimed in Claim 23 wherein in the heat absorbing coating the phase change material has a melting point between about 425°F and about 475°F. 29. A method as claimed in Claim 23 wherein in the heat absorbing coating the shell of each micro-capsule is constructed of a metal or a polymer. 30. A method as claimed in Claim 29 wherein the shell of each micro-capsule is constructed of copper. 31. A method as claimed in Claim 23 wherein in the heat absorbing coating the shell of each micro-capsule has a thickness of from about Iμ to about lOμ. 32. A method as claimed in Claim 23 wherein in the heat absorbing coating each micro-capsule has a diameter of from about 25 to about 200 . AMENDED CLAIMS [received by the International Bureau on 22 January 1998 (22.01.98); original claims 11, 12, 23 and 24 cancelled; original claims 10, 13-22 and 25-32 amended; remaining claims unchanged (4 pages)] 1. A heat absorbing coating comprising: a) a plurality of micro-capsules each comprising an encapsulant shell and a heat absorbing material within said shell; and b) a carrier for transporting the micro capsules, said carrier being adherable to a substrate and throughout which the micro-capsules are dispersed. 2. A heat absorbing coating as claimed in Claim 1 wherein the heat absorbing material is a phase change material . 3. A heat absorbing coating as claimed in Claim 2 wherein the phase change material is chosen from the group consisting of polyethylene, polypropylene, polywax and combinations thereof. 4. A heat absorbing coating as claimed in Claim 2 wherein the phase change material has a melting point between about 425 °F and about 475 °F. 5. A heat absorbing coating as claimed in Claim 2 wherein the shell is constructed of a metal or a polymer. 6. A heat absorbing coating as claimed in Claim 5 wherein the shell is constructed of copper. 7. A heat absorbing coating as claimed in Claim 2 wherein the shell has a thickness of from about Iμ to about IQμ . 8. A heat absorbing coating as claimed in Claim 2 wherein each micro-capsule has a diameter of from about 25 to about 200 . 9. A heat absorbing coating as claimed in Claim 2 wherein the carrier is a sprayable polymer matrix. 10. (Amended) An aircraft structure having thereon a heat absorbing coating comprising: a) an aircraft structure surface; b) a heat absorbing coating on the structure surface, said coating comprising a plurality of micro-capsules each comprising an encapsulant shell and a heat absorbing material within said shell, the heat absorbing material comprising phase change material; and c) a carrier for transporting the micro capsules, said carrier being adherable to a structure surface and throughout which the micro- capsules are substantially homogeneously dispersed. 11. CANCELED. 12. CANCELED. 13. (Amended) A structure as claimed in Claim 10 wherein the structure is a leading edge of the aircraft. 14. (Amended) A structure as claimed in Claim 10 wherein the structure is an engine exhaust nozzle of the aircraft. 15. (Amended) A structure as claimed in Claim 10 wherein the phase change material is chosen from the group consisting of polyethylene, polypropylene, polywax and combinations thereof. 16. (Amended) A structure as claimed in Claim 10 wherein the phase change material has a melting point between about 425 °F and about 475 °F. 17. (Amended) A structure as claimed in Claim 10 wherein the shell is constructed of a metal or a polymer. 18. (Amended) A structure as claimed in Claim 10 wherein the shell is constructed of copper. 19. (Amended) A structure as claimed in Claim 10 wherein the shell has a thickness of from about Iμ to about lOμ. 20. (Amended) A structure as claimed in Claim 10 wherein each micro-capsule has a diameter of from about 25μ to about 200//. 21. (Amended) A structure as claimed in Claim 10 wherein the carrier is a sprayable polymer matrix. 22. (Amended) A method of protecting aircraft structure surface from thermal erosion, the method comprising applying a heat absorbing coatin'y uuLU" TTe aircraft structure surface in an amount sufficient to absorb a sufficient amount of heat from the aircraft structure surface to substantially inhibit thermal erosion, said coating comprising a plurality of micro- capsules each comprising an encapsulant shell and a heat absorbing material within said shell, the heat absorbing material comprising phase change material, and a carrier adherable to the aircraft structure surface for transporting the micro capsules and throughout which the micro-capsules are dispersed. 23. CANCELED. 24. CANCELED. 25. (Amended) A method as claimed in Claim 22 wherein the structure is a leading edge of the aircraft. 26. (Amended) A method as claimed in Claim 22 wherein the structure is an engine exhaust nozzle of the aircraft. 27. (Amended) A method as claimed in Claim 22 wherein in the heat absorbing coating the phase change material is chosen from the group consisting of polyethylene, polypropylene, polywax and combinations thereof . 28. (Amended) A method as claimed in Claim 22 wherein in the heat absorbing coating the phase change material has a melting point between about 425 °F and about 475 °F. 29. (Amended) A method as claimed in Claim 22 wherein in the heat absorbing coating the shell of each micro-capsule is constructed of a metal or a polymer. 30. (Amended) A method as claimed in Claim 22 wherein the shell of each micro-capsule is constructed of copper. 31. (Amended) A method as claimed in Claim 22 wherein in the heat absorbing coating the shell of each micro-capsule has a thickness of from about Iμ to about 10//.

Claims: 32. (Amended) A method as claimed in Claim 22 wherein in the heat absorbing coating each micro-capsule has a diameter of from about 25// to about 200//.

Inventors: CLARKE JAMES A, PERSIANI CARMINE, CLARKE, JAMES, A., PERSIANI, CARMINE
Applicants: NORTHROP GRUMMAN CORP, NORTHROP GRUMMAN CORPORATION
Application year: 1997
Main classification: C08K9
IPC codes: B05D5, B64C1, C09D5, C09K5