Fluted-Core Braiding for Flexible-Blanket-Insulation Thermal Protection Systems

Tailorable Advanced Blanket Insulation (TABI) has been developed as a thermal protection system for future transatmospheric vehicles. TABI is produced in weaving looms at low rates and is very expensive. Foster-Miller proposes an improved textile process for TABI. Two flat braiders simultaneously produce parallel 0@/+0/-0 triaxial flat fabric facesheets. The axial (O@) tows run alternately through both facesheets via synchronized transfer creels. Crossover of axial tows forms the ribs between the facesheets. Ceramic batting insulation can be incorporated into the flutes during braiding. Due to the inherently faster rate of braiding versus weaving, and the elimination of the flute "stuffing" operation, this process should lower the cost of TABI. Furthermore, Foster-Miller has developed braiding machinery that has 25X the fiber capacity of current braiders; thus dramatically reducing setup and downtime. Another advantage of braided TABI is that triaxal fabrics are stronger than simple 0/90 wovens. In Phase 1, Foster-Miller will validate the machinery concept to form braided fluted core TABI. The program team includes McDonnell- Douglas (SSTO program), and an expert in commercialization of advanced textiles. Phase II would involve fabrication of a high volume TABI braider and a parallel effort to develop private sector applications for TABI.