Microtruss Reinforced Cryogenic Insulation Assembly
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Solution Overview
Problem
Current cryogenic propellant vessel insulation technologies, such as spray-on foam insulation, fail to meet the strength and reusability requirements for multi-mission flight environments due to cracking, delamination, and spalling under cryogenic temperatures and mechanical loads, and the addition of honeycomb reinforcement increases vehicle weight and costs.
Innovation Solution
A microtruss reinforced cryofoam insulation assembly is used, where a stochastic foam material encases a microtruss structure with interconnected truss members and nodes, providing a structural core that enhances mechanical and thermal performance while reducing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If honeycomb core is added to reinforce foam insulation, then mechanical strength and resistance to spalling are improved, but vehicle weight increases substantially
Solution Approach 1:
The patent applies composite materials by combining foam insulation with a microtruss structure to create a hybrid insulation system. The microtruss provides mechanical reinforcement while the foam provides thermal insulation, achieving both strength and weight reduction compared to traditional honeycomb-foam composites
Solution Approach 2:
The patent changes the structural parameters of the reinforcement from macro-scale honeycomb cells to micro-scale truss members. This parameter change reduces the volume and weight of the reinforcement structure while maintaining its mechanical support function for the foam insulation
2Weight of moving object
If foam insulation is used alone, then weight is reduced, but the foam cracks, delaminates, and spalls under cryogenic temperatures and mechanical loads
Solution Approach 1:
The patent uses composite materials by integrating a microtruss structure within the foam insulation. The microtruss acts as a reinforcement skeleton that prevents the foam from cracking and delaminating under cryogenic conditions while maintaining the lightweight advantage of foam insulation
Solution Approach 2:
The patent applies local quality by placing the microtruss structure specifically within the foam insulation where mechanical reinforcement is needed. The microtruss provides localized support at critical points throughout the insulation layer, preventing failure without adding unnecessary weight throughout the entire structure
3Ease of manufacture
If traditional spray-on foam insulation is used, then ease of application is improved, but the insulation fails to meet strength and reusability requirements for multi-mission flight
Solution Approach 1:
The patent applies composite materials by combining spray-on foam with a microtruss structure. The foam provides ease of application through spray-on methodology while the embedded microtruss provides the necessary mechanical strength for multi-mission reusability, creating a composite system that achieves both manufacturing ease and structural performance
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
The microtruss reinforced cryofoam insulation assembly offers improved resistance to mechanical and thermal stresses, reducing spalling and delamination, and maintains a lower weight compared to traditional insulation systems, thus optimizing propellant storage and reducing costs.
Implementation Method 1
a microtruss structure encased within the foam material such that the microtruss structure provides a structural core for the foam material
Implementation Method 2
The cryogenic insulation ('cryoinsulation') is required to reduce launch pad cryogen boil-off and thermally protect propellant vessels during ground servicing, launch, on-orbit, and reentry
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
A vessel (102) includes a vessel wall (104) and an insulation assembly coupled to the vessel wall. The insulation assembly includes a stochastic foam material (126) and a microtruss structure (124) encased within the foam material. The microtruss structure includes a plurality of truss members (128) interconnected at a plurality of nodes. Each truss member is in contact with the foam material such that the microtruss structure provides a structural core for the foam material.