SBIR-STTR Award

Long duration storage of large quantities of cryogenic fluids for propulsion, power, and life-support is an essential requirement for long-term missions into space. The behavior of active and passive cryogenic fluid management (CFM) is paramount to the reliability of a spaceship and cryotank storage. Therefore, efficient and reliable insulation materials are key to the success of space missions. Aspen Aerogels proposes to develop a Multi-Layer Aerogel Insulation (MLAI) system to meet NASA's CFM needs. Aerogel has been demonstrated to be more durable and reliable than MLI, at a lower weight and reduced cost with comparable thermal performance. During this program, Aspen Aerogels will validate the key process step for a next generation aerogel manufacturing technology to enable the fabrication the proposed aerogel material. This new process is also expected to enable cost reduction of aerogel materials in general, a requirement to penetrate larger commercial thermal insulation markets. Development of the proposed MLAI system will provide NASA with a long-term CFM solution for space applications.

Potential NASA Commercial Applications:
(Limit 1500 characters, approximately 150 words) Low weight, ease of installation and overall mechanical and thermal performance of aerogels as a spacer material will serve as a durable and more reliable replacement for NASA's traditionally used multi-layer insulation (MLI). Durability improvements will reduce maintenance costs and extend the period of cryogen storage and the life expectancy of the insulation system. In addition to spacecraft and other cryogen storage, applications including EVA suits, gloves, and footwear could also benefit from the thin and low density aerogel technology. The proposed insulation material will also find use in terrestrial applications, such as improved and durable insulation material for cryogenic fluid storage and transfer pipelines in preparation for launch.

Potential NON-NASA Commercial Applications:
(Limit 1500 characters, approximately 150 words) Successful development of a multi-layer aerogel insulation system will be immediately useful for a wide variety of cryogenic applications such as cryogenic storage tanks and transfer lines for LNG, LN2, etc. Thin aerogel would also be highly applicable to the very large apparel insulation market. Additionally, reducing aerogel cost through this process will allow much broader penetration into existing insulation markets, including building and construction.

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.) Aerogels Composites Cryogenic/Fluid Systems Fluids Heat Exchange

Cryogenic fluid management (CFM) is a critical technical area that is needed for the successful development for future space exploration. A key challenge is the storability of LH2, LCH4, and LOX propellants for long durations. The storage tanks must be well insulated to prevent over pressurization and venting, which lead to unacceptable propellant losses for long-duration missions to Mars and beyond. Aspen Aerogels validated the key process step for a next generation aerogel manufacturing technology to enable the fabrication of thin, low density aerogel materials. Multi-Layer Aerogel Insulation (MLAI) system prototypes were prepared using sheets of these aerogel materials that have superior thermal performance exceeding that of the current state of the art insulation for space application, MLI, across the vacuum range tested (0.01 – 100 millitorr). The exceptional properties of this system include a new breakthrough in high vacuum cryogenic thermal insulation, providing a durable material with excellent thermal performance at a reduced cost when compared to longstanding state-of-the-art MLI systems. During the Phase II Program, further refinement and qualification/system-level testing of the MLAI system will be performed for use in cryogenic storage applications.

Potential NASA Commercial Applications:
(Limit 1500 characters, approximately 150 words) The material developed in the Phase II effort could have a variety of applications within NASA. Thin low density aerogel material could potentially be used to insulate cryotanks and cryogen transfer pipelines for ground processing, satellite thermal management, and cryogen storage for space applications. Aspen has been in discussions with United Launch Alliance, NASA Kennedy Space Center and Yetispace to test the MLAI system on real-world tanks such as VATA or the CRYogenics Orbital TEstbed (CRYOTE). This real-world testing will be used to advance the TRL level of the insulation system from 5 (at the end of Phase II) to 6 - 7. Development and optimization of Aspen's new process of making thin and low density aerogels will greatly assist NASA to improve its insulation for cryogenic fuel tanks, cryogenic fuel transfer lines, spacesuit and internal insulation on future generations of re-usable launch vehicles.



Potential NON-NASA Commercial Applications:
:
(Limit 1500 characters, approximately 150 words) The new insulation system from this program will also have far reaching benefits for both military and commercial applications. The potential for the use of this material exists for durable and reliable insulation systems for any cryogenic, high vacuum or thin, flexible applications including appliances, airliner fuselage, LNG fuel storage tanks and transfer lines, and apparel.

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.) Aerogels Cryogenic/Fluid Systems Isolation/Protection/Shielding (Acoustic, Ballistic, Dust, Radiation, Thermal)