Abstract: A robust, chemically, structurally, and thermodynamically compatible ablative gap filler that can be processed with ease is provided. The gap filler uses a carbon phenolic mixture that has nearly the same material property characteristics as the adjacent PICA or carbon phenolic tiles. The gap filler is applied into the gaps using an innovative processing approach that involves preparation of a ‘dry mixture’ of the ingredients, which is then packed manually or robotically (if needed) into the gaps. During the packing process, the dry mixture may be vented, and pressed periodically to ensure that there are no trapped voids. After each gap is adequately filled with the mixture, the assembly is bagged and cured in the oven at about 250 or 300° F. for about 1.5 to 2 hours. The gap filler thereby forms a bond with the adjacent PICA or carbon phenolic tiles, without degrading or modifying the properties at any of the interfaces (e.g., with the tiles, adhesives, substrate, etc.).

Abstract: A pyrolyzing flexible ablator comprising a flexible substrate and a pyrolyzing material that will pyrolize upon exposure to a heat flux greater than 5 W/cm2, the pyrolyzing material being bonded to the flexible substrate.

Abstract: A low-to-medium mass density ablative thermal protection system (TPS) comprises a phenolic-based core member comprising a honeycombed plurality of cells separated by cell walls; and an ablator material comprising a carbonaceous material and a phenolic resin material filling the cells. The ablator material may further comprise silica and phenolic resin microspheres. Embodiments include fabricating the ablative TPS by filling the cells of the core member with a liquid slurry or dry mixture of the ablator material, followed by degassing, drying, and curing of the ablator material.

Abstract: A lightweight insulating sandwich tile (110) having applications such as spacecraft and reusable launch vehicle thermal protection is disclosed. In one embodiment, the lightweight insulating sandwich tile (110) includes an outer structural facesheet (120) that is bonded or co-cured with an inner insulating core (130). The outer structural facesheet (120) is comprised of carbon-carbon and includes an oxidation resistant layer (140) on an outer surface thereof. The oxidation resistant layer (140) may comprise a coating or surface treatment of, for example, MoSi2, amorphous SiCN, amorphous SiCBN, Ti3SiC2, HfC, HfO2, HfB2, SiC, Ir, and ZrB2. The inner insulating core (130) is comprised of bonded discontinuous carbon fibers, a network of vitreous carbon ligaments, carbon aerogel, or graphite felt or a hybrid combination of these materials.

Abstract: The invention is a collapsible tire assembly for a vehicle designed for traveling over terrain. In detail, the tire assembly includes a rim rotatably mountable to the vehicle. An outer tube expandable from a stored condition to an expanded condition is attached to the rim. The outer tube includes side portions and a center tread portion for making contact with the terrain when in the expanded condition. A mechanism is included for mounting the side portions of the outer tube to the rim such that the outer tube forms a chamber. An inner tube is mounted within the chamber expandable from a stored condition within the chamber to an expanded condition expanding the outer tube to the expanded condition such that the center tread portion is supported by the inflated inner tube and the tire assembly is suitable for moving the vehicle over the terrain.

Abstract: The present invention is directed to a multifunction structure (MFS) in which electrical/electronic componentry, thermal control and structural support are integrated into a monolithic structure that is particularly useful in spacecraft applications. The multifunctional structure is also designed to be modular so that the electrical/electronic componentry can be repaired or replaced.