SBIR-STTR Award

Human exploration requires advances in cryogenic propellants for missions to Earth orbit, cis-lunar, Mars and beyond. NASA is interested in improving thermal insulation for future Mars missions, including Evolvable Mars Campaign, Mars Landers and Mars ISRU cryogenic fuel storage on Mars surface. Cryogenic propellants have the highest energy density of any chemical rocket fuel, propel most NASA and commercial launch vehicles, and would be used for Mars Lander EDL/ascent. Cryogenic propellants require good thermal insulation. Improvements in propellant storage and transfer are a critical need for future NASA missions, with zero boil off of cryogenic propellant an important goal. High performance insulation is needed for future Mars missions to store liquid methane obtained from the Mars regolith and stored on Mars surface. Quest Thermal Group proposes to design and develop an innovative, lightweight thermal insulation system, designed to perform and insulate cryogenic propellants in multiple environments, such as in-air on Earth prelaunch and launch ascent, in-space cruise phase, on-Mars surface and during Mars Lander ascent. Multi-Environment MLI (MEMLI) is a novel multi-functional thermal insulation system that uses a ventable/sealable, lightweight supported vacuum shell, integrated and supported by Load Bearing MLI layers specifically tuned for Mars atmosphere. MEMLI will be engineered to provide high performance in-air, in-space and on-Mars, could provide <130 W/m2 in-air, <0.25 W/m2 in-space, <0.75 W/m2 on Mars surface with a robust, lightweight system with a mass about 1 kg/m2.Phase I goals are to develop a new high performing insulation structure capable of supporting Mars missions and prove feasibility of the MEMLI concept for future NASA programs. A MEMLI prototype will be modeled, designed, built and tested for thermal performance in multiple environments.

Potential NASA Commercial Applications:
(Limit 1500 characters, approximately 150 words) Multi-Environment MLI (MEMLI) might be the best thermal control system for Mars missions, capable of providing high thermal performance for all Mars mission phases, including in-air, in-space and on-Mars operation. Successful testing of MEMLI might lead to a commercially ready product from Quest Thermal and Ball Aerospace for future infusion into new NASA missions or vehicles, such as Evolvable Mars Campaign, Mars Lander or for Mars ISRU cryogen storage and preservation.The NASA In-Space Propulsion Systems Roadmap, April 2012, calls "Zero Boil Off storage of cryogenic propellants for long duration missions" the #2 ranked technical challenge for future NASA missions. The NASA Thermal Management Systems Roadmap (April 2012) states "performance and efficiency of cryogenic systems will have to significantly increase in order to enable the missions being considered over the next 20 years" [Ref 2]. It also states "New materials capable of ascent venting without performance loss or physical damage must be developed and demonstrated". The Roadmap further indicates "insulation schemes effective during ground and ascent phases while still offering optimal performance for long duration on orbit storage are needed". MEMLI may have numerous advantages for future NASA missions and needs. The multi-functionality and high performance in various environments could be applicable to various missions.

Potential NON-NASA Commercial Applications:
(Limit 1500 characters, approximately 150 words) Quest Thermal Group, and our partner in the aerospace market Ball Aerospace, continue to work diligently to promote and get infused our new technologies. IMLI will fly on the Ball Aerospace/NASA Green Propellant Infusion Mission, IMLI will fly on a Remote Refueling Mission 3 experiment on the Station, we continue to work with ULA on getting several new technologies on on-ramps to new launch vehicles, and the same effort to interest Boeing with our launch vehicle systems for SLS. Clearly, an insulation system designed for outstanding performance on Mars will have limited non-NASA use, although, perhaps one day commercial launch providers such as SpaceX might also benefit from this technology.Several aerospace prime contractors are now following with interest Quest and Ball Aerospace development of IMLI and related insulation systems. Use of a high performance VCMLI system to replace SOFI would be of interest enabling improved payload capacity in cryogenic upper stages, such as Vulcan ACES and SLS cryogenic upper stage development. LRMLI has strong application for insulating LH2 tanks for High Altitude Long Endurance UAVs, with discussions with Boeing regarding use on Phantom Eye.IMLI and derivatives might be able to provide improved thermal insulation for storage and preservation of cryogens for a wide variety of industrial uses, such as insulation for dewars for LHe, LH2, LN2 and LOX, for commercial, medical, industrial and research uses.

Technology Taxonomy Mapping:
(NASA's technology taxonomy has been developed by the SBIR-STTR program to disseminate awareness of proposed and awarded R/R&D in the agency. It is a listing of over 100 technologies, sorted into broad categories, of interest to NASA.) Active Systems Cryogenic/Fluid Systems Fuels/Propellants Isolation/Protection/Shielding (Acoustic, Ballistic, Dust, Radiation, Thermal) Passive Systems Pressure & Vacuum Systems Smart/Multifunctional Materials Storage

Human exploration requires advances in cryogenic propellant storage for missions to Earth orbit, cis-lunar, Mars and beyond. NASA has need of new technology offering high performance insulation for Mars missions, including Mars LOX or LCH4 surface liquefaction and storage and Mars Lander/Ascent Vehicle. Quest Thermal Group has developed Multi-Environment MLI (MEMLI), a novel multi-functional thermal insulation system that uses a thin lightweight semi-rigid Vacuum Shell supported by Quest IMLI layers and spacers for low heat flux and optimized for Mars atmospheric pressure. Quest engineers designed, modeled, analyzed, fabricated and tested a novel multi-functional insulation capable of providing high thermal performance both in-space and on-Mars surface for Mars missions. A thin metal semi-rigid vacuum shell is optimally supported by Quest IMLI spacers, providing low heat flux and low mass. A 10-layer MEMLI prototype provided low 0.19 W/m2 heat flux both in-vacuum and at 4.5 torr CO2 (105-210K), with a low mass of 1.5 kg/m2. Multi-Environment MLI was successfully proven feasible, is at TRL4, and remains a strong candidate for NASA Mars surface liquefaction and Mars Lander needed new technology.This Phase II program will continue developing MEMLI, with focus on further development of lightweight, supported Vacuum Shells for use on more real world tanks, development of flight-like hardware for vacuum control, increasing robustness and durability, and maturing the technology. Tasks in the Phase II program include validation of Mars mission requirements, Phase I review, updating structural and thermal models, continued development of very thin welded semi-rigid vacuum shells (down to 0.005” thick) studying their application, performance and durability for Mars missions. MEMLI will be built, installed and tested on larger, more complex cryogenic tanks for performance in all mission environments (in-air prelaunch, in-space cruise, and on-Mars surface).

Potential NASA Commercial Applications:
(Limit 1500 characters, approximately 150 words) NASA has critical needs for improved cryogenic storage technology, including active and passive insulation. Mars missions have other demanding requirements, including the ability for low heat flux in Mars atmosphere, as well as during in-space travel, with durability and low mass. Quest designed, built, tested and demonstrated good performance from new Multi-Environment MLI (MEMLI) technology, which offers thin, lightweight vacuum shells supported by IMLI layers and spacers. MEMLI may offer one third to one half the heat flux of equal layers of conventional netting-MLI, with a thin 0.010? Al vacuum shell, and MEMLI may have one-third the mass of conventional MLI and conventional vacuum shell.MEMLI, with equal heat flux in-space and on-Mars, and providing sufficient durability at low mass, is a strong candidate to insulate LOX or LCH4 storage tanks from Mars surface liquefaction activities, may prove useful for Mars Lander/Ascent Vehicle cryogenic management needs, and the thin vacuum shell offers better thermal performance in-air than SOFI, with a relatively durable metal vacuum shell, potentially offering new capabilities insulating launch vehicles.Thin, lightweight vacuum shells may provide new capabilities and benefits for NASA space exploration missions and spacecraft.



Potential NON-NASA Commercial Applications:
:
(Limit 1500 characters, approximately 150 words) Quest Thermal develops & promotes new technologies. IMLI will fly on GPIM, IMLI will fly on a RRM3 flight experiment, Quest is working with ULA on several new technologies for launch vehicles. Clearly, an insulation system designed for outstanding performance for Mars missions will have limited non-NASA use, although, perhaps SpaceX might benefit from this technology.MEMLI provided good thermal performance and potentially provides new capabilities and benefits for launch vehicles and spacecraft, depending on their mission and requirements. MEMLI, for example, provides a lower heat flux than Spray On Foam Insulation, at near equal mass, with much greater robustness than SOFI.Several aerospace prime contractors are now following with interest Quest and Ball Aerospace development of IMLI and related insulation systems. LRMLI (and variants such as CLRMLI or VCMLI) could significantly improve upper stage cryotank thermal insulation, reducing cryopropellant boiloff losses and increasing payload capacity for missions with long coasts. Use of high performance VCMLI to replace SOFI would improve payload capacity in cryogenic upper stages, such as Vulcan and SLS. ULA funded in 2016 a subcontract to Ball and Quest to do early development and testing of VCMLI, in hopes of using it on an upcoming Delta IV Heavy mission, NROL-44, where the VCMLI would reduce boiloff from the Delta Cryogenic Second Stage LH2 tank.

Technology Taxonomy Mapping:
(NASA's technology taxonomy has been developed by the SBIR-STTR program to disseminate awareness of proposed and awarded R/R&D in the agency. It is a listing of over 100 technologies, sorted into broad categories, of interest to NASA.) Cryogenic/Fluid Systems Fuels/Propellants Isolation/Protection/Shielding (Acoustic, Ballistic, Dust, Radiation, Thermal) Passive Systems Smart/Multifunctional Materials