Novel load responsive multilayer insulation with high in-atmosphere and on-orbit thermal performance

► Load Responsive MLI dynamically connects spacers supporting integrated vacuum shell. ► LRMLI in-vacuum has 78× lower heat leak than SOFI with 8× mass advantage. ► LRMLI in-air has 18× lower heat leak than SOFI with 1.6× lower mass. ► LRMLI in-air has 16× lower heat leak than aerogel with 5× lower mass. ► LRMLI has higher thermal performance than SOFI or aerogels for insulating cryogens. Aerospace cryogenic systems require lightweight, high performance thermal insulation to preserve cryopropellants both pre-launch and on-orbit. Current technologies have difficulty meeting all requirements, and advances in insulation would benefit cryogenic upper stage launch vehicles, LH2 fueled aircraft and ground vehicles, and provide capabilities for sub-cooled cryogens for space-borne instruments and orbital fuel depots. This paper reports the further development of load responsive multilayer insulation (LRMLI) that has a lightweight integrated vacuum shell and provides high thermal performance both in-air and on-orbit. LRMLI is being developed by Quest Product Development and Ball Aerospace under NASA contract, with prototypes designed, built, installed and successfully tested. A 3-layer LRMLI blanket (0.63cm thick, 77K cold, 295K hot) had a measured heat leak of 6.6W/m2 in vacuum and 40.6W/m2 in air at one atmosphere. In-air LRMLI has an 18× advantage over Spray On Foam Insulation (SOFI) in heat leak per thickness and a 16× advantage over aerogel. On-orbit LRMLI has a 78× lower heat leak than SOFI per thickness and 6× lower heat leak than aerogel. The Phase II development of LRMLI is reported with a modular, flexible, thin vacuum shell and improved on-orbit performance. Structural and thermal analysis and testing results are presented. LRMLI mass and thermal performance is compared to SOFI, aerogel and MLI over SOFI.