Spacecraft Thermal Insulation Blanket Spacer Sealing
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Solution Overview
Problem
The existing thermal insulation blankets for spacecraft, such as those using Multi-Layer Insulation (MLI), generate particulate contamination from Dacron fibers during handling and vibrations, which can lead to malfunctions in optical instruments and payload systems, and are difficult to clean once in space.
Innovation Solution
A thermally insulating blanket design with a spacer system that includes sheets of Kapton or similar materials, which are heat-welded to the insulating layers to create a sealed environment around through-holes, preventing Dacron fibers from escaping during attachment to a spacecraft, using a fixing element with a rod and retaining mechanism to secure the blanket.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the mattress is fixed mechanically using through-holes and clips, then the attachment reliability is improved, but particulate contamination occurs due to Dacron fibers escaping through the holes
Solution Approach 1:
The solution divides the through-hole into two functional zones: an outer hole for mechanical attachment and an inner sealed hole for fiber containment. The spacer wall segments the hole structure, creating distinct functional regions that simultaneously achieve secure attachment and contamination prevention
Solution Approach 2:
The spacer acts as an intermediary element between the Dacron fibers and the external environment. This intermediate structure provides a sealed barrier that prevents fiber escape while allowing the mechanical fixing system to operate effectively through the same opening
2Ease of manufacture
If the mattress is stamped and fixed using fixing elements, then the ease of manufacture is improved, but the sealed environment is compromised allowing fiber escape
Solution Approach 1:
The fixing process is segmented into two independent operations: first creating the through-hole for mechanical attachment, then adding the spacer to create the sealed environment. This segmentation allows each function to be optimized independently while maintaining overall system effectiveness
Solution Approach 2:
The spacer is installed as a preliminary protective measure before final assembly and testing. This preliminary action ensures the sealed environment is established in advance, preventing fiber contamination during subsequent handling and operations
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 solution effectively prevents particulate contamination, ensuring a sealed attachment that maintains thermal and optical integrity, preventing fiber escape and ensuring reliable operation of spacecraft instruments.
Implementation Method 1
sheets of Kapton or similar materials, which are heat-welded to the insulating layers to create a sealed environment
Implementation Method 2
a spacecraft, for example a satellite or a space probe, against the effects of localized heating from the sun and against radiation heat loss
Data Source
Figure 1~3
Figure 4~5
AI summary
The mattress (2) has a plastic spacer (16) including first sheet (22) and second sheet (24), each provided with through-holes for receiving a rod (18) of a fastening element (14), where diameter of the through-hole of the first sheet is lower than diameter of a through-hole of upper and lower outer insulating layers (4, 8) and an inner insulating layer (6). An outer peripheral edge (28) of the first sheet is sealingly secured to the inner layer, while another outer peripheral edge (30) of the second sheet is sealingly secured to the lower outer layer. : The insulating layers are made of Dacron(RTM: condensation polymer). The spacer is made of Kapton 150 FWN019(RTM: two-layer, polyimide fluoropolymer dispersion-coated heat-fusible composite film) and Kapton 150 FWR019(RTM: two-layer, polyimide fluoropolymer dispersion-coated heat-fusible composite film). The spacer has an insulating washer (36) made of material selected from epoxy resin, plastic-reinforced graphite and glass. An independent claim is also included for a method for fixing a mattress to a support. USE : Thermally multi-layer insulating mattress for insulating a spatial vehicle e.g. satellite or space probe. ADVANTAGE : The outer peripheral edges of the sheets are sealingly secured to the inner insulating layer and the lower outer insulating layer respectively, so that the portion of the first sheet and a portion of the second sheet are fixed to the wafer of the insulating layers, thus preventing contamination of the payload of the spatial vehicle by one of the components e.g. Dacron(RTM: condensation polymer), inside the insulation mattress, while ensuring better functioning of optical instruments or payload installed in the vehicle. The design of the mattress ensures better sealing between the mattress and the support, while reducing risks of particulate pollutants. DESCRIPTION OF DRAWINGS : The drawing shows a cross-sectional view of a thermally insulating mattress with a fixing element. 2 : Thermally insulating mattress 4, 8 : Upper and lower outer insulating layers 6 : Inner insulating layer 14 : Fastening element 16 : Plastic spacer 18 : Rod 22, 24 : Sheets 28, 30 : Outer peripheral edges.