Thermal management composite heat shield

Abstract

A thermal management system and methods for use are disclosed. The thermal management system comprises a shield portion and a dissipation portion. The shield portion may comprise a hot side skin, a conduction layer, an insulation layer, and a cool side skin. The dissipation portion may comprise a fin array. Heat absorbed by the shield portion is partially or fully conducted to the dissipation portion for transfer to the ambient environment. The thermal management system may be employed as an aircraft wheel heat shield, an automotive brake heat shield, a gas turbine heat shield, an electronic heat sink, and in various other applications where heat shielding and/or heat transfer are desirable.

1 . A method of manufacturing a thermal management system, comprising:
 forming a shield section comprising a cylindrical first structure positioned to receive, in a radial direction, heat generated by a heat source comprising an aircraft brake, the cylindrical first structure disposed coaxial to an aircraft wheel by a method comprising:
 coupling the cylindrical first structure to a conductive layer, the conduction layer comprising a cylindrical second structure disposed coaxially to the cylindrical first structure and at least partially radially overlapping the cylindrical first structure, thermally coupled to the cylindrical first structure, for conducting the heat in a axial direction to a dissipation apparatus, wherein the cylindrical second structure has a radius, wherein the cylindrical second structure comprises a carbon fiber structure configured with a thermal conductivity in the axial direction greater than about 100 watts per meter-Kelvin; 
 coupling the conductive layer to an insulation layer; 
 coupling the insulation layer to a cool side skin; 
   
       thermally coupling the shield section to a heat dissipation apparatus, the heat dissipation section comprising an array of fins, the array of fins comprising longitudinal fins configured such that the longitudinal fins overlap each other on an inner radial side and such that a plurality of radially aligned airflow openings are formed on an outer radial side of each fin in the array of fins, wherein radially aligned airflow openings are not formed on the inner radial side of each fin. 
     
     
         2 . The method of  claim 1 , wherein the coupling of the hot side skin to the conductive layer further comprises at least one of vacuum resin transfer and warm pressing the hot side skin and the conductive layer at a temperature of about 225 degrees Celsius to about 325 degrees Celsius. 
     
     
         3 . The method of  claim 1 , wherein the shield section has a density of at least about 1.3 grams per cubic centimeter and up to and inclusive of 2.2 grams per cubic centimeter.