Composite material structure with integral fire protection

In a flight vehicle, a load-bearing composite material structure with integral thermal and flame protection, said structure being positioned to separate a designated fire zone from other portions of the vehicle, and said structure comprising a plurality of layers of composite material;

• said layers including a plurality of inner layers, and an outer layer on an outer surface of said structure that faces and is exposed to said designated zone;
• said outer layer and each of said inner layers including a matrix material that maintains its structural integrity at temperatures of about 1200.degree. F. for at least about 5 minutes;
• said outer layer including a reinforcing fibrous flame barrier that is embedded in said matrix material and that is sufficiently flame resistant to prevent penetration of a flame with a temperature of about 2000.degree. F. for at least about 15 minutes;
• and each of said inner layers including a reinforcing fibrous material that is embedded in said matrix material and that is sufficiently strong to provide predetermined load-bearing characteristics;
• wherein all of the layers are bonded together to form a single, integral load-bearing and substantially fireproof structure.

A method of providing a fire zone in a flight vehicle with a load-bearing composite material structure and of protecting said structure from high temperatures and fire in said zone, said method comprising:

• forming a plurality of layers of composite material into a desired shape;
• providing each such layer with a matrix material that maintains its structural integrity at temperatures of about 1200.degree. F. for at least about 5 minutes;
• reinforcing one of said layers with a fibrous flame barrier that is sufficiently flame resistant to prevent penetration of a flame with a temperature of about 2000.degree. F. for at least about 15 minutes;
• reinforcing the rest of the layers with a fibrous material that is sufficiently strong to provide predetermined load-bearing characteristics;
• bonding all of the layers together to form a single, integral load-bearing and substantially fireproof structure;
• and positioning said one of said layers on an outer surface of said structure;
• and
• positioning said integral fireproof structure to bear loads, with said outer surface facing and exposed to said fire zone.