Fabric Ring Thermal Close-Out for Spacecraft Aperture Sealing
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Solution Overview
Problem
Existing thermal protection systems for space vehicles, such as bonded plugs, are costly and prone to thermal damage during re-entry, and they do not effectively manage heat penetration through access holes.
Innovation Solution
A thermal protection close-out system featuring a ring with a fabric sleeving outer layer and insulation inner layer, where the ring is formed by folding and stitching the sleeving to create a controlled aperture that can expand for tool access while minimizing heat ingress, using ceramic materials for enhanced protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a bonded plug is used to close the hole, then thermal protection is provided, but the cost increases significantly and the plug is subject to thermal damage
Solution Approach 1:
The close-out is divided into multiple functional layers: an outer fabric layer providing structural integrity and flexibility, an intermediate insulation layer blocking heat transfer, and an inner core layer providing thermal resistance. This segmentation allows each layer to address specific thermal protection needs while collectively preventing heat penetration without the drawbacks of bonded plugs.
Solution Approach 2:
The close-out employs a composite structure combining fabric materials for flexibility, ceramic or other high-temperature insulation materials for thermal resistance, and adhesive layers for bonding. This composite approach creates a multi-functional component that provides both thermal protection and structural integrity while resisting thermal damage during re-entry.
2Object-affected harmful factors
If a bonded plug is used to close the hole, then thermal protection is provided, but the cost increases significantly
Solution Approach 1:
The close-out is divided into multiple functional layers: an outer fabric layer providing structural integrity and flexibility, an intermediate insulation layer blocking heat transfer, and an inner core layer providing thermal resistance. This segmentation allows each layer to address specific thermal protection needs while collectively preventing heat penetration without the drawbacks of bonded plugs.
Solution Approach 2:
The fabric-based close-out with insulation layers provides a cost-effective alternative to expensive bonded plugs. The design uses readily available materials such as fabric and ceramic insulation that can be manufactured at lower cost while still providing adequate thermal protection for the mission duration.
3Object-affected harmful factors
If the aperture is kept small for thermal protection, then heat ingress is minimized, but tool access capability is reduced
Solution Approach 1:
The close-out incorporates a flexible fabric construction that allows the aperture to dynamically adjust its size. The fabric can be flexed or manipulated to enlarge the opening for tool access, then returns to its original configuration to minimize heat ingress when not in use. This dynamic behavior resolves the contradiction between maintaining a small aperture for thermal protection and enabling larger openings for tool access.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution provides a cost-effective, flexible, and thermally protective access mechanism that reduces heat penetration and allows for rapid installation/uninstallation of thermal protection fabrics, protecting small instrumentation ports and maintaining structural integrity during re-entry.
Implementation Method 1
an inner layer of the ring including insulation, the outer layer enclosing the inner layer
Data Source
AI summary
Thermal protection close-outs are disclosed. A disclosed example thermal protection close-out includes a ring defining an aperture extending therethrough, an outer layer of the ring including a fabric sleeving, and an inner layer of the ring including insulation, the outer layer enclosing the inner layer.