Ambient Pressure-Dried Ormosil Hybrid Aerogel Composite Blankets for Advanced Space Suit Insulation

NASA is seeking innovative thermal insulation solutions for extravehicular activity (EVA) suits on the Martian surface. In this program, Optowares Inc. proposes to develop “Ambient Pressure (AP)-Dried Ormosil Hybrid Aerogel Composite Blankets for Advanced Space Suit Insulation”. The key innovation in our approach is to combine already-demonstrated unique aerogel material systems, functional (nano)additives, and aerogel processing methods to simultaneously improve mechanical properties, adhesion of aerogel matrix to fibers, and rubbery effects. Due to their synergistic effects, our proposed AP-dried Ormosil hybrid aerogel composite approaches will overcome not only the weak and brittle dust-generating nature of conventional silica aerogel composite materials, but also the stiffness, flammability, and high thermal conductivity of conventional organic aerogel composite materials. This is achieved while providing low density and superior thermal insulation associated with the nanopore structure of aerogel materials. As a result, our proposed AP-dried aerogel composites will demonstrate good flexibility and drape, less/no dust generation from different deformation fields, and good cycling performances, along with good thermal insulation. Additionally, our proposed aerogel composites can be economically produced without using the expensive CO2-supercritical drying equipment or the similarly expensive freeze-drying (FD) equipment, and the excessive hydrophobicity agents. Overall, our proposed aerogel composites will provide superior thermal insulation and inherent radiation protection suitable for NASA advanced EVA suits, space hardware, and vehicles as well as many other aerospace, military, and commercial insulation applications. Therefore, the overall aims of this program are i) to demonstrate the feasibility of our proposed aerogel composite approach to fully satisfy NASA’s requirements, and ii) to provide economic viability of the scaled-up commercial manufacturing.

Our proposed Ormosil aerogel composites will improve the thermal and mechanical insulation for EVA suits on the Martian surface. The Ormosil aerogels are air, water, and vacuum capable and thus could be incorporated into new single-suit designs for a broad spectrum of astronaut missions. The resilient, tough, and less dusty Ormosil aerogels can be extended for use as cryogenic insulation material in difficult vibration and acoustic environments. Gloves, footwear, habitats, and helmets could also potentially use the new insulation materials. Other potential applications include use as insulation in commercial and military aircraft, cryogenic tanks, liquefied gas transport, gloves, footwear, systems for warming, storing, and transporting food and medicine, sleeping bags and pads, military, and recreational tents, etc. The Ormosil aerogel materials may be recycled for use as impact modifiers or fillers for conventional plastics.

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