Non-Traditional Insulation for Flight Weight Composite Pressure Vessels

Interceptors require lighter weight upper stage rocket motor and Attitude Control System (ACS) components to achieve performance goals for next generation interceptors. Lower density, higher temperature internal insulation materials will reduce weight in the interceptor rocket motor, homing and control propulsion and ACS components. In ongoing programs, SDC is developing a composite insulated pressure accumulator (PA) for interceptors. The composite overwrap has proven to be lighter weight compared to a metal design; however, the insulation inside the composite PA accounts for a large percentage of the PA weight. Improvements in rocket motor mass fraction of next generation boosters can be realized by reducing mass of inert components. In order to reduce inert mass, SDC is already utilizing improved higher temperature resin systems and highly repeatable manufacturing processes to develop a lightweight interceptor large diameter rocket motor case (RMC). To address lightweight interceptor propulsion pressure vessels and further reduce inert mass, SDC is proposing a Phase I SBIR program to reduce weight of insulated composite PAs and RMCs through the following innovations: non-traditional insulations with higher temperature capabilities compared to traditional internal insulations; insulation sizing through thermal analysis; manufacturability and insulation integration; and hot gas testing to quantify insulation capabilities. Approved for Public Release 14-MDA-8047 (14 Nov 14)