Layered composite thermal insulation system for nonvacuum cryogenic applications

A problem common to both space launch applications and cryogenic propulsion test facilities is providing suitable thermal insulation for complex cryogenic piping, tanks, and components that cannot be vacuum-jacketed or otherwise be broad-area-covered. To meet such requirements and provide a practical solution to the problem, a layered composite insulation system has been developed for nonvacuum applications and extreme environmental exposure conditions. Layered composite insulation system for extreme conditions (or LCX) is particularly suited for complex piping or tank systems that are difficult or practically impossible to insulate by conventional means. Consisting of several functional layers, the aerogel blanket-based system can be tailored to specific thermal and mechanical performance requirements. The operational principle of the system is layer-pairs working in combination. Each layer pair is comprised of a primary insulation layer and a compressible radiant barrier layer. Vacuum-jacketed piping systems, whether part of the ground equipment or the flight vehicle, typically include numerous terminations, disconnects, umbilical connections, or branches that must be insulated by nonvacuum means. Broad-area insulation systems, such as spray foam or rigid foam panels, are often the lightweight materials of choice for vehicle tanks, but the plumbing elements, feedthroughs, appurtenances, and structural supports all create “hot spot” areas that are not readily insulated by similar means. Finally, the design layouts of valve control skids used for launch pads and test stands can be nearly impossible to insulate because of their complexity and high density of components and instrumentation. Primary requirements for such nonvacuum thermal insulation systems include the combination of harsh conditions, including full weather exposure, vibration, and structural loads. Further requirements include reliability and the right level of system breathability for thermal cycling. The LCX system is suitable for temperatures from approximately 4 K to 400 K and can be designed to insulate liquid hydrogen, liquid nitrogen, liquid oxygen, or liquid methane equipment. Laboratory test data for thermal and mechanical performance are presented. Field demonstration cases and examples in operational cryogenic systems are also given.