SBIR-STTR Award

S. D. Miller and Associates proposes to investigate a new class of thermal insulations that will enable thermal protection systems (TPS) on ceramic matrix composite (CMC) hot structures and Hypersonic Inflatable Aerodynamic Decelerators (HIAD). One insulation will embed silicon carbide aerogel in silicon carbide fibers to create a super-efficient, flexible insulation optimized for use at temperatures of 3500F and pressures >10 Torr. Another will demonstrate a lightweight, load bearing insulation that has borosilicate microballoons embedded in a borosilicate fiber matrix. The research team has prior experience developing a family of thermal insulations that have opacifiers embedded in a flexible fiber matrix. Testing has proven that these opacified fibrous insulations (OFI) are twice as efficient as unopacified insulations at temperatures >2000F and pressures <10 Torr. The proposed work will build on that proven concept by developing super-efficient, flexible insulations with aerogels, intumescents and microballoons embedded in silicon carbide, zirconia and silica fiber matrices. This will significantly reduce the weight of TPS on future NASA missions, reducing the cost of missions to Mars and other planets.

Potential NASA Commercial Applications:
(Limit 1500 characters, approximately 150 words) Research at NASA by Walker et al. "Preliminary Development of a Multifunctional Hot Structure Heat Shield" indicates that the TPS on the SpaceX Dragon could be reduced by 151 lbs. if super-efficient flexible blanket insulations are used in combination with a CMC hot structure. It is predicted that weight savings could be even greater on Mars entry vehicles, depending on the size of the vehicle and the entry trajectory.

Potential NON-NASA Commercial Applications:
(Limit 1500 characters, approximately 150 words) The Army, Air Force and DARPA have strong interest in long range, high speed vehicles. The proposed class of insulations will make those vehicles more efficient, more reliable and more effective. The methods of making these materials are expected to be lower than some less effective alternate materials, which may enable industrial applications in oil refineries and automobiles.

Technology Taxonomy Mapping:
(NASA's technology taxonomy has been developed by the SBIR-STTR program to disseminate awareness of proposed and awarded R/R&D in the agency. It is a listing of over 100 technologies, sorted into broad categories, of interest to NASA.) Entry, Descent, & Landing (see also Planetary Navigation, Tracking, & Telemetry)

Gas conduction and radiation are the two important heat transfer mechanisms in highly porous reusable thermal protection systems used for planetary entry of space vehicles. The relative magnitude of the two varies depending on altitude, temperature and the planet. Usually radiation is more significant at lower pressures and at higher temperatures. Gas conduction is more dominant at higher pressures and lower temperatures. In most planetary entries, both modes of heat transfer are significant. Typical flexible or rigid refractory ceramic fiber Thermal Protection System (TPS) such as Advanced Flexible Reusable Surface Insulation (AFRSI) and Shuttle tiles can take high temperatures, can reduce gas conduction at lower pressures, and scatter radiation at higher temperatures. There is a need for more efficient TPS with lower mass, reduced thickness and significantly lower thermal conductivity to make inter planetary missions possible. In order to achieve this goal, insulations need to be developed that can further reduce gas conduction and radiation heat transfer compared to standard refractory ceramic fiber insulations. The overall objective of the Phase II program is to migrate and optimize proven paper making concepts to fabricate robust, flexible and cost efficient, fiber reinforced aerogels, without sacrificing the thermal and mechanical qualities, in large sections suitable for application on High Speed Vehicles (HSV�s). Further investigation in Phase II would focus on production methods and recipe optimization for this new class of thermal insulations. Embedding materials with advantageous properties into fibrous mats allows tailoring the temperature and flexibility requirements to meet the needs of specific missions.

Potential NASA Commercial Applications:
(Limit 1500 characters, approximately 150 words) NASA is developing an inflatable thermal protection system known as Hypersonic Inflatable Aerodynamic Decelerator (HIAD). It consists of a giant cone of inner tubes assembled sort of like a child's stacking ring toy may some day help cargo, or even people, land on another planet, return to Earth or any destination with an atmosphere.The HIAD could give NASA more options for future planetary missions, because it could allow spacecraft to carry larger, heavier scientific instruments and other tools for exploration. Improved thermal insulations will play a key role in HIAD and other TPS of the future.



Potential NON-NASA Commercial Applications:
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(Limit 1500 characters, approximately 150 words) According to the Department for Communities and Local Government, 118,760 new homes were built in 2014. This creates a potential market for 320 million square feet of thermal house wrap each year.

Technology Taxonomy Mapping:
(NASA's technology taxonomy has been developed by the SBIR-STTR program to disseminate awareness of proposed and awarded R/R&D in the agency. It is a listing of over 100 technologies, sorted into broad categories, of interest to NASA.) Aerogels Ceramics Entry, Descent, & Landing (see also Astronautics) Entry, Descent, & Landing (see also Planetary Navigation, Tracking, & Telemetry) Passive Systems Textiles