Lockheed Martin Corporation

The Aerospace Corporation

Ilc Dover, Inc.

Suraj Prakash Rawal

William H Willcockson

Frank Mark Kustas

Richard A Hund

Edward J Simburger

David M Barnett

Thomas W Giants

Daniel R Morgenthaler

James H Matsumoto

Stephen Emerson Scarborough

Edward Nathan Harris

Janine M Thornton

Alan R Perry

Alec Garcia, Iii

Craig H Marshall

John K H Lin

Jarvis T Songer

Scott R Stolpa

Thomas W Kerslake

Kevin P Makowski

Wei Shih

Jonathan Robert Day

Laminated carbon-carbon composites can be used as an ablative material, but they are often prone to delamination under thermally induced interlaminar shear and tension. Graded carbon-carbon composites with a sacrificial or ablative layer that is integral with one or more underlying layers and not fully dense can address these issues and provide other advantages. Such graded carbon-carbon composites can include a densified base layer containing a first portion of a carbonaceous matrix, and an outer ablative layer that is integral with the densified base layer and contains a second portion of the carbonaceous matrix. The carbonaceous matrix in the densified base layer has a first porosity, and the carbonaceous matrix in the outer ablative layer has a second porosity that is higher than that of the densified base layer. Methods for forming graded carbon-carbon composites can include heating a partially densified base layer and a carbonaceous matrix precursor above a carbonization temperature.

Graded carbon-carbon composites with an integral ablative layer and methods for production thereof

A robust, chemically, structurally, and thermodynamically compatible ablative gap filler that can be processed with ease is provided. The gap filler uses a carbon phenolic mixture that has nearly the same material property characteristics as the adjacent PICA or carbon phenolic tiles. The gap filler is applied into the gaps using an innovative processing approach that involves preparation of a 'dry mixture' of the ingredients, which is then packed manually or robotically (if needed) into the gaps. During the packing process, the dry mixture may be vented, and pressed periodically to ensure that there are no trapped voids. After each gap is adequately filled with the mixture, the assembly is bagged and cured in the oven at about 250 or 300&#xb0; F. for about 1.5 to 2 hours. The gap filler thereby forms a bond with the adjacent PICA or carbon phenolic tiles, without degrading or modifying the properties at any of the interfaces (e.g., with the tiles, adhesives, substrate, etc.).

Carbon phenolic ablative gap filler

A pyrolyzing flexible ablator comprising a flexible substrate and a pyrolyzing material that will pyrolize upon exposure to a heat flux greater than 5 W/cm, the pyrolyzing material being bonded to the flexible substrate.

Pyrolizing flexible ablator material

A low-to-medium mass density ablative thermal protection system (TPS) comprises a phenolic-based core member comprising a honeycombed plurality of cells separated by cell walls; and an ablator material comprising a carbonaceous material and a phenolic resin material filling the cells. The ablator material may further comprise silica and phenolic resin microspheres. Embodiments include fabricating the ablative TPS by filling the cells of the core member with a liquid slurry or dry mixture of the ablator material, followed by degassing, drying, and curing of the ablator material.

Carbon-phenolic ablator monoliths and their methods of manufacture

A flexible inflatable hinge includes curable resin for rigidly positioning panels of solar cells about the hinge in which wrap around contacts and flex circuits are disposed for routing power from the solar cells to the power bus further used for grounding the hinge. An indium tin oxide and magnesium fluoride coating is used to prevent static discharge while being transparent to ultraviolet light that cures the embedded resin after deployment for rigidizing the inflatable hinge.

Thin film solar cell inflatable ultraviolet rigidizable deployment hinge

A lightweight insulating sandwich tile ( ) having applications such as spacecraft and reusable launch vehicle thermal protection is disclosed. In one embodiment, the lightweight insulating sandwich tile ( ) includes an outer structural facesheet ( ) that is bonded or co-cured with an inner insulating core ( ). The outer structural facesheet ( ) is comprised of carbon-carbon and includes an oxidation resistant layer ( ) on an outer surface thereof. The oxidation resistant layer ( ) may comprise a coating or surface treatment of, for example, MoSi , amorphous SiCN, amorphous SiCBN, Ti SiC , HfC, HfO , HfB , SiC, Ir, and ZrB . The inner insulating core ( ) is comprised of bonded discontinuous carbon fibers, a network of vitreous carbon ligaments, carbon aerogel, or graphite felt or a hybrid combination of these materials.

Oxidation resistant insulating sandwich tiles

The present invention discloses an insulated reentry heat shield for minimizing heat transfer to a spacecraft structure or the like during atmospheric reentry. The heat shield ( ) comprises an outer heat resistant layer ( ) including an ablative first material backed by an inner insulating layer ( ) including an insulating second material. The outer and inner layers ( ) are bonded to one another by a middle layer ( ) disposed therebetween. The middle layer is formed by disposing at least one layer of a phenolic loaded third material between the outer and inner layers and heating all three layers simultaneously to remove phenolic volatiles from the middle layer. In one embodiment, the ablative first material is carbon-carbon, the insulating second material is carbon foam, and the phenolic loaded third material is carbon scrim cloth. The present invention also discloses a method for use in constructing a heat shield. The method includes the steps of preparing an outer heat resistant layer comprised of an ablative first material and attaching the outer heat resistant layer to an inner insulating layer comprised of an insulating second material. The outer heat resistant layer is attached to the inner insulating by disposing at least one layer of a phenolic loaded scrim cloth or felt material between the outer heat resistant layer and the inner insulating layer and heating the outer heat resistant layer, the layer(s) of phenolic loaded scrim cloth or felt material, and the inner insulating layer simultaneously to remove phenolic volatiles from the scrim cloth or felt material.

Insulated reentry heat shield

The invention is a collapsible tire assembly for a vehicle designed for traveling over terrain. In detail, the tire assembly includes a rim rotatably mountable to the vehicle. An outer tube expandable from a stored condition to an expanded condition is attached to the rim. The outer tube includes side portions and a center tread portion for making contact with the terrain when in the expanded condition. A mechanism is included for mounting the side portions of the outer tube to the rim such that the outer tube forms a chamber. An inner tube is mounted within the chamber expandable from a stored condition within the chamber to an expanded condition expanding the outer tube to the expanded condition such that the center tread portion is supported by the inflated inner tube and the tire assembly is suitable for moving the vehicle over the terrain.

Storable tire assembly for a vehicle

Modular and multifunctional structure

A thermally conductive structure for transferring heat energy transversely, relative to a heat source interconnected to the structure, is disclosed. The structure generally includes a plurality of non-metallic thermal plugs insertable into a corresponding plurality of cells of a honeycomb core. Each of the thermal plugs are primarily axially thermally conductive. The honeycomb core is sandwiched between first and second panels, the heat source being mounted on the first panel. As such, the structure with high through the thickness thermal conductivity (e.g., greater than 200 W/m .degree.K) and conductance primarily transversely transfers heat energy from the heat source to the second panel via the plurality of thermal plugs.

Growing community of inventors

Littleton, CO, United States of America

Suraj Prakash Rawal