WO2020190349A2 - Systèmes expansibles pour l'espace - Google Patents

Systèmes expansibles pour l'espace Download PDF

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Publication number
WO2020190349A2
WO2020190349A2 PCT/US2019/068506 US2019068506W WO2020190349A2 WO 2020190349 A2 WO2020190349 A2 WO 2020190349A2 US 2019068506 W US2019068506 W US 2019068506W WO 2020190349 A2 WO2020190349 A2 WO 2020190349A2
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WO
WIPO (PCT)
Prior art keywords
shell layer
expandable
expandable system
shell
layer
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PCT/US2019/068506
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English (en)
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WO2020190349A3 (fr
Inventor
Brian Aiken
Maxim De Jong
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Thin Red Line Aerospace Ltd
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Priority to PCT/US2019/068506 priority Critical patent/WO2020190349A2/fr
Publication of WO2020190349A2 publication Critical patent/WO2020190349A2/fr
Publication of WO2020190349A3 publication Critical patent/WO2020190349A3/fr

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B64—AIRCRAFT; AVIATION; COSMONAUTICS
    • B64G—COSMONAUTICS; VEHICLES OR EQUIPMENT THEREFOR
    • B64G1/00—Cosmonautic vehicles
    • B64G1/22—Parts of, or equipment specially adapted for fitting in or to, cosmonautic vehicles
    • B64G1/52—Protection, safety or emergency devices; Survival aids
    • B64G1/58—Thermal protection, e.g. heat shields
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B64—AIRCRAFT; AVIATION; COSMONAUTICS
    • B64G—COSMONAUTICS; VEHICLES OR EQUIPMENT THEREFOR
    • B64G1/00—Cosmonautic vehicles
    • B64G1/22—Parts of, or equipment specially adapted for fitting in or to, cosmonautic vehicles
    • B64G1/52—Protection, safety or emergency devices; Survival aids
    • B64G1/56—Protection against meteoroids or space debris
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04H—BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
    • E04H15/00—Tents or canopies, in general
    • E04H15/20—Tents or canopies, in general inflatable, e.g. shaped, strengthened or supported by fluid pressure

Definitions

  • the present invention relates to lightweight, expandable systems for space vehicles and structures.
  • such systems include insulation and shielding systems that can survive free stream exposure during spacecraft flight and maintain high protection and insulation performance on orbit, in space, and/or on or near celestial bodies.
  • a launch vehicle or carrier rocket is a rocket used to carry a payload from the surface of a planet or other celestial body into orbit or outer space.
  • a launch system includes the launch vehicle, the launch pad, and other infrastmcture.
  • An example of a launch vehicle is the Space Launch System (SLS).
  • the SLS is an American Space Shuttle-derived heavy expendable launch vehicle.
  • the SLS is part of NASA's deep space exploration plans including a manned mission to Mars.
  • the NASA Authorization Act of 2010 envisions the transformation of the NASA Constellation program's Ares I and Ares V vehicle designs into a single launch vehicle usable for both crew and cargo, similar to Constellation’s Ares IV.
  • the SLS is to be the most powerful rocket ever built with a total thrust greater than that of the Saturn V, putting the SLS into the super heavy-lift launch vehicle class of rockets.
  • Hydrogen and oxygen are gases at room temperature and can only be liquefied at extremely low temperatures: Hydrogen boils at -252.87 °C (20.28 K; -423.17 °F) and Oxygen boils at -182.96 °C (90.19 K; -297.33 °F) at 101.325 kfa (760 mmHg) pressure. Maintaining liquid hydrogen and liquid oxygen at such extreme temperatures in their cryogenic state poses enormous technical challenges.
  • cryogenic liquids must be meticulously insulated from any source of heat, such as the ambient environment before and after rocket launch; from rocket engine exhaust; and from aerodynamic heating during flight through the atmosphere.
  • This insulative functionality that simultaneously withstands high dynamic pressures in the free stream environment of the rocket’ s ascent phase, is traditionally addressed with foam insulation.
  • Foam insulations are relatively heavy and potentially susceptible to sloughing off under influences such as inclement weather prior to launch, propellant tank icing damage, as well as in-flight effects such as vibration, free stream dynamics, and bird strikes— all factors which have the potential to reduce insulation effectiveness for the remainder of a mission, or worse, to compromise launch vehicle survivability.
  • MLI Multi- Layer Insulation
  • MLI assemblies or“blankets” are not well suited for coverage of large cryogenic tanks. These traditional assemblies are usually formed into a mosaic of custom panels which require numerous interfacing attachments, seams between panels, and structural quilting, all of which result in heat losses that limit performance. Closeouts along the MLI panel peripheries inherently introduce parasitic heat leaks which are further exacerbated by localized compression of the MLI foil stack. In particular, the abutment of adjacent MLI panels requires additional closeout complexities to simultaneously permit trapped gas venting yet also overlap of adjacent MLI panels to prevent heat transfer. The process of panel joining is a labor-intensive seaming operation that commonly must be performed after the tank is built, adding to system build time.
  • High thermal efficiency of an MLI blanket requires all constituent layers to be separated from adjacent layers by full coverage fabric scrim, foam spacers, or other compression resistant standoffs to preclude contact between adjacent layers and to eliminate the potential for thermal “shorting” that would render the traditional MLI insulation ineffective. Inspection for thermal shorting contact between adjacent shell layers is also difficult to verify after assembly of an MLI system.
  • IMLI Integrated Multi-Layer Insulation
  • Debris shielding includes functionality such as required for Micro-Meteoroid and Orbital Debris (MMOD) protection.
  • MMOD Micro-Meteoroid and Orbital Debris
  • debris shielding includes armor with two or more plates that are spaced a distance apart, which is aptly called spaced armour.
  • the spaced armour configuration reduces the penetrating power of projectiles by causing projectiles to tumble, deflect, deform, and/or disintegrate with the projectile’s passage through each successive armour plate.
  • a Whipple shield is a spaced armor shield that protects a spacecraft or space borne structure from damage due to collision with micrometeoroids and other minor debris travelling at high speed relative to the spacecraft or space borne structure (generically referred to as MMOD).
  • Whipple shields are named after Fred Whipple who first suggested such shields in 1946 and referred to it as a "meteor bumper".
  • Whipple shields consist of a relatively thin outer bumper layer spaced some distance from the main hull of the spacecraft or space borne structure. The outer bumper is not expected to stop the incoming particle or even remove much of its energy.
  • the outer bumper is designed to fragment the particle and disperse its resultant debris, dividing the original particle energy among many fragments that conically fan out between the initial impact with the shield and the hull of the spacecraft or space home structure.
  • the original particle energy is dispersed over a larger wall area of the spacecraft hull or space borne structure, which is more likely to withstand the relatively minor fragment impacts.
  • the shield can be configured with a multitude of successive bumper shell layers to allow for a hull to be built to a thickness needed for structural integrity with minimized consideration for MMOD protection. While the shield assembly itself adds little additional weight, multiple thin shield layers increase the protective capability of the system over selection of an increased hull thickness.
  • Such a Whipple shield protected spacecraft or space borne structure is lighter weight than a spacecraft or space borne structure with adequately robust hull designed to stop the meteoroids directly.
  • Embodiments of the invention are directed to an expandable system for at least partially surrounding a stmcture in space.
  • the expandable system can include a first shell layer and a second shell layer disposed contiguously adjacent to the first layer.
  • the expandable system can include a tension connector disposed between the first shell and second shell layer.
  • the tension connector can be connected to adjacent surfaces of the first shell layer and the second shell layer.
  • the tension connector can retain in tension the first shell layer relative to the second shell layer prior to, during, and/or after expansion of the expandable system.
  • the second shell layer is passively distended relative to the first shell layer by internal gas expansion.
  • the internal gas expansion can occur due to a pressure differential due to a reduced environmental pressure.
  • the second shell layer can be an outermost shell layer of the expandable system.
  • the second layer can include one or more vent aperture. The one or more vent aperture allowing for gas to be released from inside the second shell layer of the expandable system to the environment outside of the expandable system.
  • the tension connector can be substantially inelastic. In some embodiments, the tension connector is foldable prior to expansion of the expandable system.
  • the tension connector can have a greater length than cross sectional thickness. For example, the length of the tension connector can be at least 100 times larger than the thickness of the tension connector.
  • the tension connector can be not resistant to collapsing. As such, the tension connector can be highly collapsible under a negligible amount of force or even its own weight.
  • the tension connector can be strip of material.
  • the tension connector can be in the form of a strip of material adhered at opposing ends to the adjacent surfaces of the first shell layer and the second shell layer.
  • the expandable system can include an extendable support member.
  • the tension connector can be statically supported by the extendable support member when the expandable system is fully expanded.
  • the second shell layer can be an outermost shell layer and an expandable support member including a support batten can support the second shell layer.
  • the second shell layer can include a batten sleeve, the support batten extending within the batten sleeve. And, the support batten can be extendable and configured to lock in an extended state.
  • the support batten can in a circumferential, spiral, or meridional direction relative to a central axis of the expandable system.
  • the expandable system can include a rigidizing media.
  • the rigidizing media can be applied to the second shell layer or an exterior cover.
  • the rigidizing media maintains the tension of the tension connector according to such embodiments.
  • the rigidizing media can include a resin and/or adhesive that hardens upon exposure to an environmental condition. And, the environmental condition can include ultraviolet light.
  • the first shell layer can be an innermost shell layer. And, the first shell layer can conform to an outer surface of the structure. In some embodiments, the first shell layer and second shell layer are passively distended by internal gas expansion due to reduced exterior pressure. In other embodiments, the first shell layer and second shell layer are actively distended. In some embodiments, the first shell layer and/or second shell layer can also be actively distended by a pump, by gas from a reservoir, or by a gas generator.
  • the structure can include a cryogenic tank surrounded at least in part by the expandable system.
  • the expandable system can include a compression system.
  • the compression system can compress the second shell layer against the first shell layer.
  • the expandable system can include an exterior cover surrounding the expandable system.
  • the exterior cover can include a fabric woven from fibers.
  • the fibers can include NEXTEL, ZYLON, and/or TECHNORA.
  • the fibers can include glass, carbon, ceramic, liquid-crystalline polyoxazole, and/or aramid.
  • the exterior cover can include a flexible radiator panel and/or a flexible solar panel.
  • the expandable system can include a release system, the release system releasing the compression system thereby allowing at least the second shell layer to distend under internal pressure.
  • the expandable system can include a heat resistant coating or film maintaining fabric integrity and providing surface finish resistant to aerodynamic force.
  • the coating or film can include silicone, a fluoropolymer, and/or fluorinated ethylene propylene.
  • the coating or film can include KAPTON.
  • the expandable system can include a plurality of additional shell layers and additional tension connectors, each tension connector connecting adjacent surfaces of adjacent shell layers.
  • the expandable system can include at least five shell layers.
  • the second layer can include a polyester or polyamide film. And, at least the second layer can incorporate a metallic film or vapor deposited metal coating. At least the second layer can a protective layer. The second layer can incorporate materials, fibers, and/or coatings shielding against debris moving at high relative speed, i.e.“debris shielding”. At least the second layer can include a shear-thickening resin, ceramic or glass fiber-based fabric.
  • At least the second layer can include a fabric woven from high-modulus debris shielding fiber. At least the second layer can include VECTRAN, ZYLON, TECHNORA, KEVLAR, or NEXTEL. At least the second layer can be laminated on one or both sides with one or more plastic films. And, in some embodiments, at least the second layer incorporates a plastic film with vapor deposited metal coating. At least the second layer can be laminated on one or both sides with KAPTON, UPILEX, or MYLAR.
  • Methods of expanding an expandable system are disclosed. Such methods can include providing the expandable system in collapsed state, transporting the expandable system to a destination, and once at the destination, the expandable system expanding into an expanded state. Certain methods include releasing an exterior cover surrounding the expandable system. And, certain methods for expansion of a system include passively expanding due to reduced environmental pressure.
  • systems include an expandable system in combination with a fairing.
  • the expandable system can be configured to expand from a collapsed position to an expanded position within the fairing.
  • a stmcture is provided with an expandable system in a collapsed state prior to expansion.
  • the expandable system can include a first shell layer having a cross- sectional area and a second shell layer disposed upon the first shell layer.
  • the second shell can be larger in cross-sectional area than the first shell layer.
  • the second layer can be folded so as to have a folded cross-sectional area substantially similar to the cross-sectional area of the first shell layer.
  • the first shell layer conforms, in some embodiments, to an outer surface of a structure.
  • the expandable structure can include a collapsed tension connector connecting opposing adjacent surfaces of the first shell layer and the second shell layer.
  • the collapsed tension connector can be folded between the first shell layer and the second shell layer in the collapsed state prior to expansion.
  • a system for surrounding at least in part a structure in space can include a first shell layer, a second shell layer disposed contiguously adjacent to the first layer, a tension connector disposed between the first shell and second shell layer.
  • the tension connector can be connected to adjacent surfaces of the first shell layer and the second shell layer. And, the tension connector can retain in tension the first shell layer relative to the second shell layer.
  • a system can include a support member pre-tensioned prior to being transported to space.
  • the support member being an extendable support member.
  • FIG. 1A (prior art) is a simplified diagram of traditional multi-layer insulation (MLI);
  • FIG. IB (prior art) graphically shows edge heat loss associated with traditional multi layer insulation (from Donabedian, Martin, and David G. Gilmore, eds. Spacecraft Thermal Control Handbook, Vol. 2. AIAA 2003);
  • FIG. 2A shows illustrations of an expandable protective system in its collapsed state
  • FIG. 2B shows illustrations of the expandable protective system of FIG. 2A in its distended state
  • FIG. 2C shows illustrations of the expandable protective system in its distended state
  • FIG. 2D shows close-up illustrations of the expandable protective system in its distended state
  • FIG. 2E shows illustrations of a telescoping distension batten
  • FIG. 2F shows diagrams schematically illustrating distension of the expandable protective system from its collapsed state to its distended state
  • FIG. 3A is a view of an expandable protective system in its packaged state and in its distended state inside an inflatable payload fairing embodiment
  • FIG. 3B is a close-up illustration of the expandable protective system in its distended state inside an inflatable launch vehicle payload fairing embodiment
  • FIG. 3C is a cross-sectional diagram illustrating a tension connector system disposed between shell layers, a batten, and a parent structure;
  • FIG. 3D shows traditional compression standoffs between MMOD shell layers for comparison to the connectivity system shown in FIG. 3C according to embodiments of the present invention
  • FIG. 4A is an illustration of an example of an expandable protective system packaged on a windswept exterior of a vehicle
  • FIG. 4B is a view of the expandable protective system of FIG. 4A in its expanded state on the exterior of the space borne vehicle;
  • FIG. 5A shows an exterior cover installation prior to tensioning
  • FIG. 5B shows the tensioned exterior cover
  • FIG. 5C is a close-up view of an exterior cover release pin loop, grommet, and tensioning buckle
  • FIG. 5D is a close-up view of examples of the components of an exterior cover closure and release mechanism
  • FIG. 6A is a view of a a parent structure with the collapsible/expandable system in its distended state
  • FIG. 6B is a cross-sectional diagram of a parent structure and the collapsible/expandable system in its collapsed state;
  • FIG. 6C is a cross-sectional diagram of the parent structure
  • FIG. 7A illustrates performance degradation of traditional MLI over ideal performance
  • FIG. 7B illustrates heat flux as function of the number of protective shield layers as measured for examples of embodiments of the present invention
  • FIG. 8A is a diagram showing a parent structure with an expandable protective system including circumferentially oriented batten extendable support members;
  • FIG. 8B is a close-up cross-sectional diagram of the end cap area of the assembly of FIG. 8A;
  • FIG. 9A is a diagram showing a parent structure with an expandable protective system including meridionally oriented batten extendable support members.
  • FIG. 9B is a close-up cross-sectional diagram of the end cap area of the assembly of FIG. 9A;
  • FIG. 10A is a diagram showing a parent structure with an expandable protective system including spiral oriented batten extendable support members.
  • FIG. 10B is a close-up cross-sectional diagram of the end cap area of the assembly of FIG. 10A;
  • FIG. 11A is a diagram showing an outermost shell layer with a rigidizing coating
  • FIG. 1 IB is a diagram showing a shell layer with a coating
  • FIG. 11C is a diagram showing a shell layer including a debris shielding material laminated with cladding layers.
  • multi-function systems can simultaneously: (a) insulate a space vehicle or space borne container from an external environment, (b) insulate a space vehicle’s cryogens from heat sources, (c) protect the vehicle from the high dynamic pressures and the high heat loads encountered in atmospheric flight, and/or (d) provide storage capability that strongly limits, or effectively eliminates, cryogenic boil-off losses once in space.
  • Such systems can also provide protective shielding to counter forms of radiation beyond thermal, as well as protect the space vehicle or space borne container from the threat of impact with MMOD.
  • the current invention can alternately be configured to specifically provide high performance thermal insulation, radiation shielding, and/or debris shielding functionality as required.
  • the innovative systems disclosed herein may fulfil any or all of the aforementioned thermal, radiative, and structural protective needs.
  • Embodiments discussed hereinafter can provide solutions to the detraction from the original Whipple shield design.
  • several embodiments provide a collapsible and accurately expandable system of protective shell layers that provide optimized shielding against debris moving at high relative speed, i.e.“debris shielding”, and MMOD protection capability while simultaneously providing near-theoretically-perfect MLI performance.
  • the design, material selection, reinforcement and spacing of such systems’ shell layers can be optimized to provide maximum MMOD protection for specific mass and/or volume constraints.
  • Such systems are further scalable with interior“parent structure” size, heat load requirement, and mission duration.
  • a spacecraft, or any other space structure that benefits from the protective attributes of the herein described expandable system, is generically referred to as“parent structure”.
  • an expandable protective system 200 is illustrated that is installed on a parent structure 220 such as on space vehicles, liquid fuel and oxygen containers, and other space structures to meet the need for multifunctional performance including provision of structure, radiation and/or thermal protection, and/or MMOD protection.
  • FIGS. 2A, 2B, 2C, and 2D includes a plurality (also referred to as a“stack” 210) of nested protective shell layers 213 that envelope a portion, or all, of the parent structure 220.
  • the shell layers 213 are disposed contiguously adjacent one-another with each shell layer 213 being of sequentially increasing size.
  • the protective shell layers 213 in this example are concentrically spaced.
  • This embodiment of the expandable shell system 200 illustrating the invention has both a collapsed state shown in FIG. 2A, and a distended, or expanded, state shown in FIGS. 2B, 2C, and 2D. The distended state shown in FIGS. 2B.
  • 2C, and 2D can be obtained through expansion of the protective shell system 200 from its collapsed state shown in FIG. 2A.
  • Expansion of the protective shell layer stack 210 introduces separation 215 shown in FIG. 2D (see also 315 shown in FIG. 3C) between the individual shell layers 213 whereby in the distended state of the expandable system 200 shown in FIGS. 2B, 2C, and 2D the individual shell layers 213 of the stack 210 are substantially concentrically spaced such that individual shell layers 213 do not directly contact one-another upon expansion.
  • an embodiment of the expandable system 200 is packaged closely around its parent structure 220, thereby substantially conforming to the outer surface 221 (see e.g. FIG. 2D) or so-called outer mold line (“OML”), of the parent structure 220.
  • OML outer mold line
  • the stack’s innermost, or base shell layer 213A remains substantially conformant to the geometry of the parent structure’s 220 outer surface 221, thereby necessarily being also dimensionally the smallest of the protective shell layers 213.
  • subsequent shell layers 213 of the shell layer stack 210 sequentially and substantially concentrically increase in size, with the outermost, or most outermost shell layer 213N (see also 313N), being dimensionally the largest layer 213.
  • Embodiments of the current invention may have one or more intermediate, or internal, shell layers 213 in addition to and positioned between the base shell layer 213A (see also 313A) and the outermost shell layer 213N (see also 313N).
  • the stack 210 of shell layers may have any number of intermediate shell layers 213.
  • only the base shell layer 213A (see also 313A) and outermost shell layer 213N (see also 313N) are implemented.
  • the desired spatial separation 215 (see also 315) of successively larger shell layers 213 in the system’s 200 distended state is facilitated by flexible tension connectors 235.
  • the flexible tension connectors 235 connect adjacent shell layers 213 to one-another and retain the alignment and spacing of connected shell layers 213.
  • the number of shell layers 213, as well as the measure of their separation 215 is predominantly tailored to the thermal and/or structural protective requirements of the expandable protective system 200.
  • the stack 210 of protective shell layers 213 can be packaged tightly around the parent structure 220.
  • the internal shell layers, represented in FIG. 2D by 213B thru 213F and in FIG 3C by 313B, and the outermost shell layer 213N (see also 313N) can incorporate folds or pleats 216 (see e.g. FIG.
  • thermal insulation With regard to thermal insulation, and as discussed in detail in Section I, in actual specific non-limiting embodiments applied by the inventors to a cryogenic tank parent structure 220 as shown in FIGS. 2A and 2B, only six (6) shell layers would be required (including 20% performance error margin) for a combined thermal insulation (MLI) functionality to meet a thermal performance driver of less than 0.5 W/m 2 heat flux (assuming a warm boundary of 220 K on orbit) and MMOD debris shielding performance driver of at least 95% probability of no shield penetration for a two-year mission duration at international space station (ISS) orbital altitude.
  • MLI thermal insulation
  • analytical models of this specific embodiment constmcted by the inventors predicted 25 times better insulation performance, in ter s of heat flux per number of layers, as compared to traditional MLI.
  • An expandable shell system disclosed herein can be used as a protective system for a cryogenic liquid tank (“cryotank”) that simultaneously constitutes the protective system’s parent structure and launch vehicle payload.
  • a cryotank parent stmcture 320 and its expandable protective system 300 are housed within a launch vehicle’s payload fairing 325.
  • a payload fairing 325 includes the nose cone 327 used to protect a spacecraft and its payload from the dynamic pressure and aerodynamic heating encountered in flight through an atmosphere.
  • the expandable protective system 300 Prior to launch, the expandable protective system 300 is collapsed and securely packaged around the cryotank 320 and within the system’s exterior cover 340 (see also 240 in FIGS 4A, 4B, 5A, and 5B; and 640 in FIG. 6A).
  • One intent of the secure packaging is to minimize the packaged volume of the system 300 while protecting the system 300 from the vibrational, acoustic, and dynamic loads associated with launch and flight of the carrier rocket.
  • the system’s 200 and 300 exterior cover 240 and 340 restrains the pressure within the shell layer stack 210 and 310 throughout the ascent of the rocket through the atmosphere, thereby preventing the stack of shell layers 213 and 313 from distending to their fully expanded configuration.
  • vent apertures 339 such as the pictured perforations in the outermost shell layer 313N allow for a gradual venting of a portion of the gas that was originally trapped within the packaged expandable protective system 300 prior to launch.
  • the rate of expandable protective system 300 venting is calibrated to preclude pressure-induced trauma to the shell layer stack 310 (also applicable to 210), and to the exterior cover 340 (also applicable to 240).
  • vent apertures 339 applied to shell layers 213 (see also 313B), and 213N (see also 313N) can take the form of perforations, openings in seam lines, openings in edge close-outs, flaps, tubes or other specifically designed vent paths, pressure release valves, and related mechanisms, active or otherwise.
  • a pressure relief system is provided that can limit or control the differential pressure between the interior volume and the environment outside of the expandable protective system 300.
  • the base shell layer 213A (see also 313A) and the outermost shell layer 213N (see also 313N) are sealingly connected to form a substantially gas-tight enclosure for the shell layer stack 210 and 310.
  • Such an embodiment can be designed to require only the outermost shell layer to be configured with a pressure relief system such as vent apertures 339 to permit gradual and calibrated venting of the shell layer stack 210 and 310.
  • a pressure relief system such as vent apertures 339 to permit gradual and calibrated venting of the shell layer stack 210 and 310.
  • the aforementioned embodiment outermost shell layer 213N and 313N can be fabricated of greater strength and/or greater gastightness material than the internal shell layers represented in FIG. 2D by 213B thru 213F and in FIG 3C by 313B.
  • Complete venting of the disclosed and claimed embodiments may be ultimately achieved by use of such methods to facilitate gradual and calibrated venting of the shell layer stack 210 and 310 which simultaneously results in the expansion of such system 200 and 300.
  • a release system of the exterior cover 340 is activated thereby allowing the protective system 300 of the current invention to expand.
  • the release system is described in section“H” and in FIG. 5.
  • Expansion of the protective system 300 is facilitated by the residual positive gage pressure within the shell layer stack 310.
  • Expansion of the protective system 300 is a controlled dynamic event whereby the pre expansion positive gage pressure within system 300 is relieved by the expansion of the residual trapped gas into the larger distended volume of the system 300.
  • any remaining gas within the stack 310 is passively released through a pressure relief system such as vent apertures 339 to the space environment, leaving the voids between successive protective shell layers 313 at the vacuum pressure level of space required for high performance MLI performance.
  • This passive expansion methodology facilitates distension of the expandable shell layers’ 313 protective and insulative system 300 upon release of the exterior cover 340 (applicable to 240 as well) without the need for an active mechanical mechanism, gas storage reservoir, gas generator, or any hazardous pressurant gas gage pressures.
  • Complete distension of the outermost shell layer 313N e.g.
  • tension connectors 335 ensures that tension is applied to tension connectors 335 (see also 225) and tension connectors 335A and 335N between any number of successive layers 313 as shown in FIG. 3C, thereby in turn ensuring spacing and full distension of all shell layers 313 outwards from the stack’s innermost, or base shell layer 313 A (see also 213A) as shown in FIGS 3A and 3B (see also FIGS. 2B, 2C, 2D).
  • the exterior cover 340 (see also 240) is retained after system expansion to provide additional debris, thermal, and/or radiation shielding, or other corollary beneficial attributes in accordance with specific mission requirements.
  • the exterior cover 340 (see also 240) of further embodiments can incorporate features such as flexible radiator panels and/or solar panels that are useful to operation of the parent structure or associated systems and services. Such features are particularly applicable to space exploration architectures such as spacecraft, inflatable habitats, airlocks, shelters, rovers, and storage tanks.
  • the systems 200 and 300 can be expanded and distended using a mechanical system, compressed gas from a reservoir or from a gas generator or other source of inflation gas. Relative to the vacuum environment of space, or at many celestial bodies, only a very low positive gage pressure is needed for expansion and distension of the protective systems 200 and 300. This translates to a minimal inflation gas requirement for implementation.
  • the systems 200 and 300 vent their inflation gas to the vacuum of space, thereafter presenting the same high-performance protective and insulation attributes described herein for other embodiments expanded with passive inflation.
  • This design and implementation approach for protective systems 200 and 300 is particularly applicable to space habitation systems; airlocks; and structures such as containers, storage tanks, and rover vehicles for exploration of celestial bodies.
  • Multi-functional systems 200 and 300 are hereby provided that can (a) insulate and protect a space vehicle or space borne structure from an external environment, (b) insulate a space vehicle’s cryogens from heat sources, (c) protect a vehicle from the high dynamic pressures and the high heat loads encountered in atmospheric flight, (d) provides storage capability that strongly limits, or effectively eliminates, cryogenic boil-off losses once in space, and (d) provide the launch vehicle, spacecraft, space borne structure with protective shielding to counter other forms of radiation besides thermal, as well as the threat of impact with MMOD.
  • the current invention can alternately be configured to specifically provide high performance thermal insulation, radiation shielding, and/or debris shielding functionality as required.
  • the innovative systems disclosed herein may fulfil any or all of the aforementioned thermal, radiative, and structural protective needs.
  • the expandable shell system 200 can be installed on the exterior of a launch vehicle, the launch vehicle being the parent structure 220 shown in FIGS. 2A-F.
  • the expandable shell system 200 can meticulously insulate containment tank parent structures 220 for the rocket’s cryogenic liquids from any source of heat. Examples of such heat sources can include the ambient environment before and after rocket launch, heat from rocket engine exhaust, and aerodynamic heating during flight through the atmosphere.
  • Traditional MLI cannot withstand an aerodynamic wind loading environment as opposed to a more robust solution such as the expandable system 200 disclosed herein.
  • the insulative functionality of the current system 200 can simultaneously incorporate a robust exterior cover 240 (see also 340) that allows the system 200 to withstand the high forces and dynamic pressures associated with the free stream environment of the rocket’s ascent phase.
  • the system’s 200 base shell layer 213A can incorporate a fastening system 217 that mates with, and connects to, a corresponding anchor system 223 on the outside of the launch vehicle 220.
  • the fastening and connecting systems 217 and 223 ensure that system 200 maintains its installed position relative to the launch vehicle axis 222 and 322 shown in FIGS. 2E and 3A respectively.
  • FIG. 4A shows the system 200 in its collapsed state for flight.
  • FIG. 4B shows the system 200 in its expanded state.
  • a wind dam 224 can be embedded within the surface or on the outside of the launch vehicle 220 to protect the windward edge of the expandable system 200 from the free stream flow.
  • the system 200 can be expanded and distended at such an altitude where the atmospheric density and free stream environment are sufficiently diminished to preclude aerodynamically induced trauma to the expanded shell system 200.
  • systems 200 and 300 provide substantially greater thermal protection with reduced mass. Furthermore, the systems 200 and 300 eliminate exposed foam that could slough off as a result of weather, propellant tank icing damage, and/or bird strikes that thereby reduce effectiveness for the remainder of a mission and potentially endanger the launch vehicle.
  • expandable shell systems 200 and 300 can incorporate extendable support members to maintain stable, long term structural support of the distended geometry of expandable shell systems 200 and 300.
  • Such extendable support members can take the form of telescoping battens in certain embodiments of the present invention.
  • outermost shell layer 213N and 313N can incorporate telescoping battens 270 and 370 that lie retracted in the collapsed state of the expandable protective system 200 as shown in FIGS. 2A and 2C.
  • These telescoping battens 270 and 370 extend to conform to the dimensions of the fully distended outermost shell layer 213N and 313N as shown in FIGS. 2B, 2D, 3B and 3C.
  • the support battens 270 and 370 can lock as shown in FIG.
  • the support battens 270 and 370 can support a passively stable and long-term protective system structural geometry that does not rely on inflation gas, foam spacers, or other compression standoffs, such as standoffs 237 between shell layers 213 shown in FIG. 3D.
  • Another embodiment takes advantage of the protective attributes of the expandable shell systems 200 and 300 associated with the expanded and fully distended state without the need for the systems 200 and 300 to expand from a collapsed state.
  • Such“pre-expanded” embodiments can simplify systems integration, and eliminate the need for an exterior cover 240, and packaging, compression, and expansion mechanisms.
  • Such embodiments also provide uninterrupted protection of a parent structure 220 and are advantageous in the absence of volume constraints, for example whereby the expanded dimension of systems 200 and 300 are smaller than the internal dimensions of launch vehicle payload fairing into which systems 200 and 300 may be transported.
  • the outermost shell layers 213N and 313N can incorporate intermittent batten sleeves 272 and 372 on its outer surface through which the support battens 270 and 370 pass.
  • the location of the batten sleeves 272 and 372 on the outer surface of the outermost shell layers 213N 313N can correspond with the attachment points of tension connectors 235 and 335 on the inner surface of the outermost shell layers 213N and 313N, for example as shown by tension connector 335N and shell layer 313N in FIG. 3C. Moving inwards towards the parent structure 220 in FIG.
  • tension connectors 235 can be radially aligned in an end-to-end fashion between successive shell layers 213 and 313 of the stacks 210 and 310 respectively, to allow radial tension loads of systems’ 200 and 300 expansion and distension to be directly transmitted through the entire shell layer stacks 210 and 310 without appreciably loading the individual shell layers 213 and 313.
  • a continuous radial tension connector structure 236 and 336 comprising an end- to-end connected sequence of individual tension connectors 235 can structurally connect the batten sleeves 272 and 372 with the base shell layers 213A and 313A of the expandable shell structures 200 and 300.
  • the base shell layer 213A (see also 313A) can incorporate reinforcing fabric or fibers, or be locally reinforced, to provide a structurally suitable substrate to which the innermost rank of tension connectors 235A and 335A can be securely connected.
  • the now extended and dimensionally locked battens 270 and 370 can apply a direct outward load on the batten sleeves 272 and 372 and the underlying tension connectors 235 and 335 thereby ensuring correct separation 215 and 315 of each concentric internal shell layer 213 and 313 of the stacks 210 and 310.
  • the support battens 270 and 370 in FIGS. 2A-F and FIG. 3C are pictured oriented in the circumferential sense 343 (see FIG. 3A) of the shell systems 200 and 300. Battens 270 and 370 can also be oriented in spiral fashion or in the meridional sense of the shell systems 200 and 300.
  • the support battens 270 and 370 can be fabricated from relatively stiff yet lightweight flexible materials, for example pultruded carbon fiber tubing. To maintain their extended geometry after expansion, the support battens 270 and 370 can incorporate any of a variety of“locking” mechanisms 274 such as biased ball locks as shown in FIG. 2E. In some particular embodiments, the support battens 270 and 370 do not require a locking mechanism after systems 200 and 300 expansion, but rather maintain their extended geometry simply by virtue of friction between the extended batten 270 and 370 and the distension-tensioned intermittent batten sleeves 272 and 372 through which the support battens 270 and 370 pass.
  • “locking” mechanisms 274 such as biased ball locks as shown in FIG. 2E.
  • the support battens 270 and 370 do not require a locking mechanism after systems 200 and 300 expansion, but rather maintain their extended geometry simply by virtue of friction between the extended batten 270 and 370 and the distension-tensioned intermittent batten sleeves 272 and 372 through which the support batten
  • an alternate embodiment of the current invention can dispense with extendable support members by incorporating rigidizing media 1004 such as resins and/or adhesives in the exterior cover 240 and 340 or outermost shell layers 213N and 313N of systems 200 and 300.
  • the rigidizing media 1004 can activate upon expansion of systems 200 and 300 and subsequently cure and harden upon exposure to prescribed environmental factors such as ultraviolet light— thereby maintaining system 200 and 300 distended geometry.
  • a different expansion and distension mechanism of shell systems 200 and 300 than the use of gas can be provided by an embodiment whereby the batten sleeves 272 and 372 of outermost shell layers 213N and 3f 3N of the embodiments 200 and 300 can incorporate battens 270 and 370 respectively of sufficient stiffness and/or spring tension to, upon exterior cover 240 and 340 release, facilitate distension of the shell layer stack 210 and 310 without the need for the earlier described trapped gas distension mechanism.
  • collapsible parent structures can be collapsible and expandable according to the teachings disclosed herein.
  • An example of such a collapsible/expandable parent structure 680 is the inflatable space habitable structure shown in FIG. 6A.
  • the example embodiment of such collapsible/expandable parent structure 680 pictured in FIG. 6A is an inflatable airlock to support astronaut Extra-Vehicular Activity (EVA) by means of the pictured EVA hatch 681.
  • FIG. 6 A also shows the OML 621 of the expanded parent structure 680, as well as the base shell layer 613A, an internal shell layer 613, and exterior cover 640 of the expandable parent structure 680.
  • Further examples of collapsible/expandable parent structures 680 are collapsible/expandable shelters, storage tanks, and propellant tanks.
  • an embodiment of the expandable shell system 600 can protect such collapsible parent structures 680 with multifunctional thermal and debris shielding attributes by virtue of the flexibility of the protective layer stack 610, such as previously described for example.
  • the protective layer stack 610 such as previously described for example.
  • collapsible/expandable parent structure 680 can include folds, pleats, constrictions, and/or other collapsible features 635 so as to be expandable from the collapsed state shown in FIG. 6B to the expanded state shown in FIG. 6C where the collapsible features 635 of the expandable parent structure 680 and shell system 600 of FIG. 6B have been unfolded, distended, or expanded as shown in FIG. 6C.
  • the expandable shell system’s 600 ability to be collapsed with folds and pleats 616 allows the shell system 600 to occupy minimum volume in concert with the diminished collapsed and packaged dimensions of collapsible/expandable parent structures 680.
  • the expandable shell system 600 for a collapsible/expandable parent structure 680 can be expanded and distended by means previously described.
  • one example of a preferred embodiment of the shell system 600 configurationally and dimensionally conforms to the collapsed parent structure 680, whereby the shell system 600 features distension maintenance battens 670 that can be tightly coiled around the collapsible/expandable parent structure 680 as schematically shown in FIG. 6B.
  • FIG. 6C shows the distended configuration of the packaged collapsed configuration shown in FIG 6B.
  • Low-friction batten sleeves 672 can facilitate reduced friction resistance expansion of the coiled battens 670.
  • Battens 670 can be securely attached to an individual batten sleeve 672 to ensure correct circumferential positioning of the support batten at time of shell system 600 expansion.
  • batten 670 is attached at its approximate center to a batten sleeve thereby minimizing the distance batten 670 needs to slide through its associated batten sleeves 672 at time of shell system 600 expansion.
  • the coiled battens 670 can assume different orientations such as circumferential, axial, or spiral with regard to the axes of the parent structure 680.
  • the individual shell layers 213 of the expandable shell system 200 can be mutually connected by tension connectors 235 as previously discussed, whereby the shell layers 213 are expanded in tension as a result of distension of the outermost shell layer 213N.
  • Conventional multi-layer insulation (MLI) blankets are an assembly of a large number (commonly 20 or more) of thermally reflective, foil-type shell layers as shown in FIG. 1A. The thermal efficiency of conventional MLI blankets requires all constituent layers to be separated from adjacent layers by full coverage fabric scrim 234 (see FIG. 1 A). As shown in FIG.
  • the tension connectors 235 and 335 of the current systems 200 and 300 respectively exhibit several vast improvements over conventional MLI functionality by virtue of, for example, (a) the relatively large distance between adjacent shell layers 213 and 313, and (b) the minimal structural capability and distribution density (i.e. large spacing) of tension connectors 235 and 335 required to maintain spacing of the shell layers 213 and 313.
  • the tension connectors 235 and 335 need only support small tensile loads during system expansion and after distension of the protective shell layer respective stacks 210 and 310.
  • the tension connectors 235 and 335 of the current expandable shell systems 200 and 300 have a much higher ratio of length to cross-sectional thickness and width than conventional spacer materials.
  • the length L of the tension connector can be at least 100 times larger, for example 375 times larger, than the thickness T of the tension connectors 235 and 335.
  • the effective result of the preceding is that the tension connectors 235 and 335 of preferred embodiments assume a gossamer, ribbon-like form.
  • Example materials for tension connectors 235 and 335 are high specific strength, high modulus plastic films such as polyimides KAPTON or UPILEX, or biaxially-oriented polyethylene terephthalate (BoPET) such as MYLAR.
  • expandable shell system 200 can have an example tension connector 235 (see also 335) length of 2.54 cm (1.0 inch) with a thickness of 0.01 cm (0.004 inch) and
  • Such expandable shell systems 200 and 300 can provide better thermal protection than traditional MLI while using fewer layers, and also better performance than so-called Integrated Multi-Layer Insulation (LMLI).
  • IMLI is an MLI design that relies on compression resistant polymer spacers to maintain shell layer separation, but in doing so precludes system collapsibility for efficient packaging.
  • the requisite large number of polymer spacers furthermore reduces IMLI performance compared with the virtual elimination of conduction as a contributing mode of heat transfer in the herein described expandable shell systems 200 and 300.
  • the virtual elimination of conduction in systems 200 and 300 also results in an analytically determinate system which can be confidently designed without costly iteration between manufacturing and verification testing.
  • FIGS. 2C and 2D a finite number of tension connectors 235 results in a faceted overall effect on the distended internal shell layers 213 and outermost shell layer 213N.
  • a minimum number of shell layer 213 facets are required to prevent contact of the base shell layer 213 A with an internal shell layer 213. Such contact would result in a thermal“short” reducing effectiveness of the insulation.
  • Sixteen such facets and the associated distribution of tension connectors 235 are shown in FIG. 2C.
  • Similar axial distribution of tension connectors 235 results in an example approximate areal distribution of only 1.7 tension connectors 235 per square meter of parent structure 220 outer surface 221 area.
  • the FIG. 2C detail view shows an embodiment design of six shell layers 213 that allow a 20% thermal margin for losses associated with penetrations, end of life (EOL) properties, and other uncertainties.
  • tension connectors 235 A detail view of tension connectors 235 is provided in FIG. 2D detailing connection of tension connectors 235 (see also FIG. 3C) to either side of each protective shell layer 213.
  • tension connectors 235 can be fabricated from ribbon-thin yet high-strength and high-modulus polymer film.
  • the close- up view of FIG. 2D on the left also shows the connection points of the outer ranks of tension connectors 235 with the batten sleeves 272 through which battens 270 pass.
  • a series of circumferential battens 270 are visible which extend along the length of the parent structure 220.
  • expandable shell embodiments 200 and 300 can include one, more, or all of protective shell layers 213A-N and 313A-N of the current expandable shell systems 200 and 300.
  • each, all, or any of shell layers 213A-N and 313A-N can incorporate debris shielding materials 1003, that may include fibers, and coatings, such as shear-thickening resins, ceramic or glass fiber-based fabrics, and/or fabric woven from high-modulus debris shielding fibers such as liquid crystal polymer VECTRAN, liquid-crystalline polyoxazole ZYLON, aramids TECHNORA or KEVLAR, or ceramic fiber such as NEXTELTM.
  • debris shielding materials 1003 may include fibers, and coatings, such as shear-thickening resins, ceramic or glass fiber-based fabrics, and/or fabric woven from high-modulus debris shielding fibers such as liquid crystal polymer VECTRAN, liquid-crystalline polyoxazole ZYLON, aramids TECHNORA or KEVLAR, or
  • the protective shell layers 213A-N and 313A-N of other embodiments can incorporate a coating 1001 on one or both sides, for example through vapor deposition of aluminum (VDA) metal or, as shown in FIG. 11C, with a cladding layer 1002 of plastic film or metal foil to produce a multi-functional shield layer 213A-N and 313A-N providing tailored thermal, or debris protection, or a combination of both protections.
  • VDA aluminum
  • FIG. 11C the cladding layer 1002 of plastic film or metal foil to produce a multi-functional shield layer 213A-N and 313A-N providing tailored thermal, or debris protection, or a combination of both protections.
  • Material selection may be based on many factors and requirements.
  • the shell layer 213 A-N and 313A-N materials and fabrics can be laminated on one or both sides with one or more plastic films such as polyimides KAPTON or UPILEX, or biaxially-oriented polyethylene terephthalate (BoPET) such as MYLAR. Selection of shell layers 213A-N and 313A-N materials can be made to also enhance other parent structure 220 needs such as radiation protection.
  • plastic films such as polyimides KAPTON or UPILEX, or biaxially-oriented polyethylene terephthalate (BoPET) such as MYLAR.
  • several embodiments may further include the exterior cover 240 that maintains the multi-layer stack 210 of protective shell layers 213A-N packaged and restrained in its collapsed configuration, for example during transport or during carrier rocket launch, ascent, and flight, but whereby the exterior cover 240 can also be released, and if desired, partially or entirely jettisoned at time and location of expansion of the expandable shell system 200.
  • the highly advantageous flexibility of the ribbon- like tension connectors 235 that connect successive protective shell layers 213 to one-another does not impede compression and packaging of the stack 210 of shell layers 213 and allows the tension connectors to advantageously conform to the reduced dimensional geometry of the collapse state of the expandable shell system 200.
  • the exterior cover 240 can also incorporate a compression system that can include a plurality of integrated compression straps 255 that permit tightening of the exterior cover 240 using tensioning buckles 257.
  • the compression system aids in packaging of the expandable shell system 200 by substantially conforming the stack 210 of protective shell layers 213 to the dimensions of the OML 221 of the parent structure 220 as shown in FIG. 5B.
  • the compression straps 255 can also feature a“stopper” which redundantly defines the prescribed packing circumference of the shell system 200 around the parent structure 220, and furthermore precludes trauma to the shell system 200 or the parent structure 220 due to over-tensioning of the exterior cover 240.
  • the tensioning buckles 257 and compression straps 255 can be removed after shell system 200 packaging in some such embodiments.
  • the exterior cover 240 can further incorporate a release system as shown in FIG. 5B.
  • the release system shown in FIG. 5B incorporates mechanically interlocking, releasable, and re- closable features of the types shown in FIGS. 5C and 5D, including grommets 265, release pins 267, or other like connectors for securing and releasing the exterior cover 240.
  • Such release systems and methods may be similar or the same as release systems in many arts, such as parachute packaging and deployment.
  • release pin loops 266 appear in grommet 265 holes, or“windows,” to receive the release system pins 267 in a fashion well-known in the parachute industry.
  • the inventors have also found proven convenience, versatility, ease of installation and closure of the exterior cover 240, as well as compression and release predictability by using military specification methods and hardware in testing.
  • the compression system releases the restraining aspect of the exterior cover 240 thereby allowing the expandable shell system 200 to expand and achieve its distended state.
  • Release can be triggered by redundant pyrotechnic cutters or by other well-known space-deployable technology means.
  • pyrotechnic cutters can sever a tensioned release cord 268 that thereafter recoils to pull the release pins 267 from their respective pin loops 266.
  • Distension of the shell layer stack 210 can be facilitated by methods and systems previously described in detail. Also, as previously described in detail herein, a distension maintenance system such as locking battens 270 and 370 can be implemented upon full expansion of the protective system’s 200 multi-layer stack 210 of protective shell layers 213, thereby maintaining the distended state of the expanded stack of shell layers 213.
  • a distension maintenance system such as locking battens 270 and 370 can be implemented upon full expansion of the protective system’s 200 multi-layer stack 210 of protective shell layers 213, thereby maintaining the distended state of the expanded stack of shell layers 213.
  • a design embodiment that simplifies packaging of the expandable shell system 200 can include a dimensionally oversized exterior cover 240 which can be loosely wrapped around the folded assembly of the expandable shell system 200 and subsequently tightened with the earlier described compression system shown in FIGS. 5A-D.
  • the exterior cover 240 (see also 340) can be fabricated of lightweight, dimensionally stable fabrics and films to allow sufficiently tight packaging of the shell layer 213 stack 210 to resist potentially damaging spacecraft dynamic launch and flight loads, and the positive gage pressure that develops within the packaged shell layer 210 stack during atmospheric flight.
  • Example fibers 5A and 5B can be fabricated from a fabric that is woven from fibers that are simultaneously of high specific strength, high modulus, and are resistant to high temperature.
  • Example fibers may be of glass, carbon, ceramic such as NEXTEL, liquid-crystalline polyoxazole such as ZYLON, or aramid such as TECHNORA.
  • the aforementioned fabric may be treated with heat resistant coatings or films that may also assist in maintaining cover 240 fabric integrity and provide surface finishes resistant to aerodynamic forces.
  • Example coatings may include silicone, or fluoropolymers such as Polytetrafluoroethylene (PTFE), Perfluoroalkoxy Alkane (PFA), or Fluorinated Ethylene Propylene (FEP).
  • An example heat resistant film that can be incorporated in exterior cover 240, 340 embodiments is polyimide such as Kapton.
  • the excess in circumferential material of the collapsed shell layer stack 210 can be captured in longitudinal pleats 216 to facilitate packaging of the expandable shell system 200.
  • Gaps between the segments e.g. six segments are distributed around the circumference of shell system 200 in FIG. 2A) of the exterior cover 240 (see also 340) are defined and bounded by the meridional 244 ranks of batten sleeve 272 (see also 372) placements which dictate the pleat 216 fold line locations.
  • the resulting circumferential 243“reduction” of excess material (and dimension) of the shell stack 210 can be complemented by a similar reduction, this time in the meridional 244 sense, of the excess shell stack 210 material enveloping of parent structure 220 end caps 218 (see FIG. 8B).
  • FIGS. 2A and 2B illustrate such expansion of the shell stack 210, from its packaged and restrained state in FIG. 2A, to its expanded, minimally pressurized, and finally vented and batten stabilized embodiment shown in FIG. 2B.
  • the tautness of each of the shell layers 213 is seen in FIG. 2B and is indicative of successful expansion of expandable shell systems 200.
  • FIG. 2F provides another schematic depiction of expansion of the shell stack 210 from its packaged and restrained state on the left in FIG. 2F to its expanded state shown on the right of FIG. 2F.
  • Another benefit of the herein described compression system of the expandable shell systems 200 and 300 is its ability to attenuate the dimensional and physical discontinuities of the packaged systems 200 and 300 and to provide more precise packaged dimensions.
  • the robust dimensional stability of the preferred pressure restraining embodiment of the shell systems 200 and 300 exterior cover 240 and 340 of the herein disclosed compression system design approach can also constrain protrusions and other irregularities of the collapsed shell layer stacks 210 and 310.
  • Each compression strap 255 shown in FIGS. 5A and 5B can cinch down to define the same, or locally requisite, prescribed packaging circumference regardless of location and regardless of the tension force required to locally compress the system 200. As such, locations of
  • Tensioning buckles 257 can be locally loosened, or release pins 267 altogether removed, to allow manipulation and optimized realignment of the packaged contents.
  • other embodiments may require the exterior cover 240 and 340 to be geometrically discontinuous or segmented to adapt to non-uniform or otherwise specific packaged content geometry.
  • the compression system hereby provides a substantially geometrically uniform exterior cover 240 and 340 surface of the expandable shell system 200 and 300. According to such embodiments, compression load is applied where most needed thereby deflecting protruding features laterally to adjacent cavities. This is especially advantageous to assist and facilitate compression, packaging, and expansion of the collapsible and expandable parent structures described earlier herein.
  • Embodiments of the exterior cover 240 and 340 can also incorporate low coefficient of friction fabrics, films, or coatings such as the earlier described fluoropolymers to readily slide over the exterior surface of the collapsed shell layer stack 210 thereby reducing frictional trauma and easing shell stack 210 compression for packaging. Such embodiments also benefit“clean” separation of the exterior cover 240 and 340 at time of system 200 and 300 expansion.
  • Embodiments disclosed herein can deliver an integrated, form-fitting multi-functional protective (e.g. thermal and/or impact protection) system.
  • the expandable protective systems 200 and 300 can offer thermal and other radiation protection, debris shielding protection, or thermal, radiation, and debris shielding protection simultaneously.
  • Various embodiments of the systems disclosed herein can eliminate the numerous challenges associated with conventional protective technologies by providing continuous single piece individual shell layers through computer-assisted operations in the cutting and seaming activities of the individual shell layers. Seam closure alignment tabs can be accurately located and cut to facilitate precise seam closure for each individual shell layer.
  • the complete stack 210 of the expandable protective system’s 200 shell layers 213 can be fabricated as a single, open, jacket-like assembly that can be wrapped around the parent structure 220 for installation. Each individual shell layer 213 is thereafter sequentially closed around the parent structure 220, starting with the base shell layer 213A.
  • the proposed design is less susceptible to human error induced performance degradations than conventional MLI designs.
  • the characteristic open architecture of the herein disclosed embodiments including spaced shell layers 213A-N readily facilitates visual inspection of the expandable protective system 200, both during fabrication and assembly, as well as after system build. Thermal shorting contact between traditional adjacent shell layers of conventional MLI blanket designs is difficult to verify after assembly, whereas shell layer 213 contact is readily visually verifiable in various designs of the current invention.
  • traditional MLI blankets require significant customization,“touch labor”, testing, and inspection
  • expandable shell systems disclosed herein can provide reliable quantified performance at reduced cost.
  • the support structures, plumbing, and other external elements and discontinuities associated with parent structure 220 integration requirements can pass through the expanded protective shell system 200 with minimal impact to system’s 200 performance since pass-through penetrations do not cause thermal shorts between the shell layers 213.
  • the architecture of the current invention can incorporate conventional star-cut perforations in the individual radiation shields, conical shapes, flaps, or shutter mechanisms of the example types implemented on the James Webb Space Telescope and on proposed configurations of orbital cryogenic propellant depots. These adaptive configurations allow maximum thermal and debris protection to be provided to the full surface area of the parent structure 220.
  • the protective system 200 disclosed herein can be an independent free-floating structure that does not require extensive attachment to the parent stmcture 220.
  • the system 200 can attach to available parent structure 220 surfaces at the end caps 218 and can be positionally restrained at parent stmcture 220 structural integration locations and plumbing penetrations thereby providing support to the protective system 200 during ground handling, launch, and flight.
  • This illustrative embodiment required only 0.25 mm (0.01 in) of cryotank wall thickness to absorb the dispersed energy of fragmented MMOD after impact with the expandable protective system 200— a value which is a rough order of magnitude less than the thickness required by the conventional Whipple shield design.
  • This embodiment represents a significant mass and performance improvement over the previous state of the art.
  • This particular design is furthermore ideally suited for protection of both the central cylindrical portion of a cryotank parent structure 220 as well as the tank end caps 218.
  • the mass“overhead” burden of the non-protective batten 270 and tension connector 235 elements of the tested shell system 200 may be only 15% of the mass of the combined MLI and MMOD shell layers 213. 57% of the system’s 200 mass pertains to MMOD shielding functionality, 4% to MLI, and notionally 24% to the pressure restraining exterior cover such as elements 240 and 340.
  • the areal density of the individual shell layer 213 offering combined MLI and MMOD design protection was approximately 360 g/m 2 (10.6 oz/yd 2 ). This is only one example of a current design and other solutions and designs are anticipated under the teachings of this document.
  • parasitic thermal conduction through the expandable shell system’s 200 concentric shell layer 213 construction is almost exclusively through the tension connectors 235 connecting adjacent shell layers 213.
  • Thermal conduction between adjacent shell layers 213 through the connecting tension connectors 235 is near-negligible due to (a) the low conductivity of the material, (b) the small cross-sectional area of individual tension connectors 235, (c) the relatively large distance between shell layers 213 desired for optimum MMOD protection functionality— and hence large tension connector 235 length, and (d) the relatively small number of tension connectors 235 needed to maintain system 200 geometric definition and stack 210 shell layer 213 spacing.
  • FIG. 7A shows the tested results of the traditional MLI as well as a theoretical“perfect performance” curve. Thermal models of the innovative designs of the systems fabricated and disclosed herein show close conformance to this theoretical“perfect performance” curve.
  • the disclosed architecture facilitates addition of specifically thermal shell layers between the shell layers incorporating MMOD protective materials, thereby optimizing both thermal insulation and MMOD shielding performance. For example, one additional MLI layer positioned between the five
  • MLI/MMOD layers reduces heat flux to less than 0.25 W/m 2 . This illustrates a significant advantage over traditional MLI.
  • the determinate thermal performance of systems 200 disclosed herein can allow design modification without lengthy and costly design and test cycles to develop manufacturing techniques and verify performance.
  • FIG. 7B shows the thermal model of the penetrating heat flux as a function of the number of individual MLI/MMOD layers according to a design previously built by the named inventors of this patent application.
  • a minimally tensioned tape 235 connected expanded system 200 eliminates the thermal shorts and mass impact seen in traditional MLI by eliminating layer- separating scrim and the required quilted fabrication structure of conventional MLI.
  • FIG. 7B shows the calculated ratio of radiative heat transfer between the shell layer stack 210 to the conductive heat transfer through the series of connecting tension connectors 235 as a function of the number of shell layers 213.
  • the inventors have found that the system architectures disclosed herein can provide a radiation dominated expandable thermal insulation shell system with a large degree of design flexibility.
  • the determinacy of this performance metric is an important attribute for the system, considering that heat flux in traditional MLI systems is generally dominated by conduction.
  • FIG. 7A where the effective conductance performance as historically compiled for MLI systems is seen to be two to five times greater than that predicted by a radiation dominated system in close accordance with the shown theoretical curve of optimum conductance.
  • the separation 215 see also 315) between the layers 213 (and 313) of the present invention presents a much greater path length for conduction as well as a minimal conductive cross-sectional area.
  • the theoretical curve can be used to precisely determine the number of layers needed for a requisite level of effective emittance. This overall performance determinacy furthermore greatly simplifies the thermal design as compared to traditional MLI.
  • the disclosed concepts also utilize continuous, uninterrupted, and substantially concentric shell layers 213 thereby presenting little impact of parasitic thermal edge effect losses, offering distinct advantage when compared to traditional MLI blankets manufactured in comparatively small sections that need to be recombined to be able to provide larger area coverage.
  • the expandable shell systems disclosed herein can define an architecture of two or more, and optimally five or more, minimally supported shell layers 213.
  • Each shell layer 213 can be separated by a gap of 25 to 50 mm (1 to 2 inches) upon expansion according to certain designs.
  • the shell system 200 and 300 configurations are also ideally suited to multi-layer MMOD shield functionality.
  • a single thick, dense MMOD shield layer must decelerate and absorb the energy of an incoming particle over a very small area thereby requiring a large amount of shield mass.
  • the incoming debris particle is shocked by the exterior shield layer causing it to fracture into smaller particles, which spread out between layers.
  • a multi-layer MMOD shield effectively distributes the particle impact energy over a much larger ultimate surface area, paving the way to a significantly reduced MMOD shield mass.
  • disclosed designs can minimize the mass required for MMOD protection by utilizing the geometry provided by the MLI design, providing a system co optimized for each function. For example, a multilayer MMOD shield for a two-year mission at ISS altitude and a 95% probability of no penetration also suggests a six-layer design as built, tested, and calculated by the inventors of this patent.
  • Three example embodiment layers of ceramic NextelTM fiber fabric each with an areal density of 270 g/m 2 (8.0 oz/yd 2 ) and distributed over a total cumulative separation of 25 cm (10 inches), provide adequate debris shielding protection.
  • Woven glass fiber fabric presents a lower cost option while offering relatively similar MMOD protection performance.
  • the MMOD layers use all of the same stmctural features required of the MLI design for little parasitic mass, allowing for independent co-optimization of the MLI and MMOD functions.
  • MMOD shield design analysis begins with the“Probability of No Penetration” (PNP) requirement.
  • PNP requirement coupled with the surface area of the vehicle, determines the allowable flux of penetrating particles. This allowable flux is compared to the flux distribution in the MMOD environment to determine the critical particle size that the shielding must protect against.
  • the MMOD shield of currently disclosed embodiments can prevent penetrations of particles smaller than the critical particle size, while the flux of particles larger than the critical size is small enough that the PNP requirement is met.
  • An example of a baseline MLI/MMOD subsystem illustrated herein can include six identical shell layers 213, each of which comprises an MMOD shielding fabric 376 sandwiched between two MLI film layers 375. This design results in the three-element protective shell 213 layup, such as shown in FIG. 3C.
  • the illustrated MLI material can include aluminum coated films such as polyimides KAPTON or UPILEX, or biaxially-oriented polyethylene terephthalate (BoPET) such as MYLAR.
  • Example SHELDAHLTM material of this type has a total thickness of 51 mhi (2.0 mil).
  • the three layers may be mutually connected employing connective mechanisms such as adhesive bonding; ultrasonic, radio frequency, or heat bonding; sewn stitching; and/or the like.
  • the elements of the layup can be continuously connected or connected at interval to keep the layup conformal during assembly and application.
  • Similar connective mechanisms such as adhesive bonding 338 may be used to structurally fasten tension connectors 335 to shell layers 313, as shown in FIG. 3C.
  • adhesive bonding 338 provides effective load transference between batten sleeves 372 (see also 272) and the system’s 300 base shell layer 313A (see also 213A) without alloying loads directly to the MLI or MMOD materials.
  • FIGS. 8A and 8B A view of a configuration which insulates a portion of the tank end is shown in FIGS. 8A and 8B.
  • FIG. 8A shows that the concept of a
  • circumferential batten 270 (see also 370) to provide tension to the external shell 213N (see also provide layer separation.
  • traditional MLI or other high performance MLI can be used to provide insulation to the upper portion of the tank.
  • manufacture, and upon deployment can include one or more of the following: a reduced mass pressure stabilized fairing system as a stand-alone benefit; reduced parasitic mass of fairing as it is retained for MMOD and thermal protection; reduction of pyrotechnic payload fairing jettison complexity compared to traditional fairing;
  • the systems disclosed herein have strong improvements for this application, either in a configuration which uses the exterior cover of the compressed and packaged MLI and MMOD subassembly as a windswept surface; as a pressure stabilized fabric nose cone for launch vehicles, SLS solid rocket boosters, and the like; and/or with a minimally pressurized inflatable payload fairing which would protect all of the underlying layers and tankage systems as proposed for orbital cryogenic depot application.
  • a minimally pressurized inflatable payload fairing which would protect all of the underlying layers and tankage systems as proposed for orbital cryogenic depot application.
  • Each of these valuable system attributes offer mission critical aspects for long mission durations required for lunar, Mars, or deep space exploration. Additional examples include zero boil-off orbital propellant depots, cryogenic coolant storage for advanced telescopes, habitat

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  • General Health & Medical Sciences (AREA)
  • Remote Sensing (AREA)
  • Aviation & Aerospace Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
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Abstract

L'invention concerne des systèmes d'isolation d'un véhicule spatial ou d'un conteneur spatial vis-à-vis d'un environnement externe ainsi que de cryogènes vis-à-vis de sources de chaleur. De tels systèmes protègent également le véhicule contre les pressions dynamiques élevées, les charges de chaleur élevées rencontrées dans le vol atmosphérique, et fournissent une capacité de stockage qui limite fortement ou élimine efficacement des pertes d'évaporation cryogéniques une fois dans l'espace. De tels systèmes comprennent une structure extensible ayant une pluralité de couches extensibles adjacentes de manière contiguë. Les couches sont reliées par une pluralité de connecteurs de tension entre des couches successives. Pour le lancement et le vol, les couches peuvent être retenues dans une position repliée. Après quoi, sortant d'un environnement de flux libre, les couches sont étendues et peuvent se verrouiller en place ou rester dans un état déployé. L'expansion crée une séparation entre les couches avec des trajets de conduction minimaux fournissant une isolation multicouche presque parfaite et une protection de débris extrêmement efficace.
PCT/US2019/068506 2018-12-24 2019-12-24 Systèmes expansibles pour l'espace WO2020190349A2 (fr)

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US4686128A (en) * 1985-07-01 1987-08-11 Raytheon Company Laser hardened missile casing
US5601258A (en) * 1994-07-25 1997-02-11 Mcdonnell Douglas Corporation Spacecraft shield
US6298765B1 (en) * 1998-12-02 2001-10-09 Mcdonnell Douglas Corporation Multi-shock assembly for protecting a spacecraft surface from hypervelocity impactors
US7954301B2 (en) * 2007-03-16 2011-06-07 Ball Aerospace & Technologies Corp. Integrated multilayer insulation
US20120175467A1 (en) * 2009-06-29 2012-07-12 Quest Product Development Corporation Micrometeoroid and orbital debris (mmod) and integrated multi-layer insulation (imli) structure
US9327848B2 (en) * 2012-06-11 2016-05-03 Bigelow Aerospace Method of deploying a spacecraft shield in space
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US10913232B2 (en) * 2016-08-30 2021-02-09 Quest Thermal Group LLC Cellular load-responsive multilayer insulation

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