Ceramic Composite Nanofiber Aerogel Insulation for EVA Suits

NASA’s EVA suits are typically made of multiple layers: an inner bladder made of polyurethane-coated nylon for suit pressure, protected by a Dacron™ restraint liner. The outer layers serve as the thermal micrometeoroid garment (TMG), with a neoprene-coated nylon liner providing thermal and micrometeoroid protection. The insulation comprises five layers of aluminized Mylar reinforced with nylon scrim spacers. While effective in vacuum and microgravity, this insulation may not suffice for Mars due to interstitial gases and extreme temperatures that can compromise its properties. Thus, alternative insulation materials must be developed. In this proposed Phase I research, MMI will develop ceramic aerogel-based insulating materials for use as thermal insulation inserts in Extra-Vehicular Activity (EVA) suits for Martian exploration. The extremes of temperatures, the presence of CO2 and the 8 Torr pressure of the Martian atmosphere necessitate the development of robust insulation materials that go beyond the currently used Mylar-based fabrics. We propose the development of a ceramic composite nanofiber aerogel that is strong, chemically stable, thermally conducting, and radiation absorbing, all of which will make it suitable for use as insulation inserts in spacesuits. Phase I will involve establishing proof of principle, and design of scaled-up systems based on optimized process parameters.

While the target application is the design of superior spacesuits suitable for use in Martian atmosphere, thermal insulation products are used in other aerospace applications as well. They will find use in spacecraft thermal protection systems (TPS) to shield vehicles during atmospheric re-entry, ensuring crew safety and spacecraft integrity. In air and spacecraft engines, thermal insulation products are required to protect surrounding structures from heat generated during operation, enhancing engine efficiency and longevity. Ceramic aerogel insulation materials have several civilian applications. They can significantly improve energy efficiency in buildings. In automobiles, they enable lighter, more fuel-efficient vehicles by insulating engine compartments. They will also find use in consumer products like extreme weather jackets, and firefighter uniforms.

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