Additive Insulative Layer for Thermal Protection System

The Heatshield for Extreme Entry Environmental Technology (HEEET) project started as a solution to the difficult entry temperatures and conditions. Its design is robust for the extreme environments that it needs to survive. HEEET Thermal Protection Systems (TPS) is fabricated with two different layers. Recently NASA Ames Research Center (ARC) is exploring other options using this system to produce robust materials that can be scaled to environmental conditions for Mars and low earth orbit (LEO) and other planetary entry. This hybrid manufacturing solution that utilizes the tight weave of the carbon layer and the low fiber volume of the phenolic thermal insulation. The application will use the weaving process established by Bally Ribbon Mills (BRM) and needle punched layer that will be developed with BRM engineering and Thomas Jefferson University (formerly Philadelphia University / Philadelphia Textile) engineering and lab equipment. The BRM team is developing a TPS that can have thermal layers added after the weaving process using needle punching techniques.nbsp;This effort is based on the work from the original proof of concept. It was proven that in an lab enviroment that a nonwoven webbing made of chopped insulation layer yarn fibers was able to bond to the insulation layer of the HEEET material. Continuing research will prove that the additive layer can be manufactured to increase the thickness while maintaining the fiber volume of the insulation layer of HEEET. This continued work will utilize two different manufacturing techniques for the nonwoven webbing that will be needle punched to the insulation layer, air laid web delivery (Rando)nbsp;and wet laid web delivery (Southeastern Nonwovens). These two techniques will be explored to scale the thickness of the Additive Insulation Layer(AIL) to 0.5quot;nbsp;opening options for variable thickness TPS with increased speed to manufacture.nbsp; nbsp;