Design, fabrication and test of Load Bearing multilayer insulation to support a broad area cooled shield

•LBMLI structurally supported a broad area cooled shield without tank standoffs.•LBMLI with BAC shield survived simulated launch ascent environment.•LBMLI reduced heat flux by 51% per layer over traditional MLI.•LBMLI/BAC successfully demonstrated a tube-on-shield active cooling concept.•LBMLI was matured with these ground tests to TRL5. Improvements in cryogenic propellant storage are needed to achieve reduced or Zero Boil Off of cryopropellants, critical for long duration missions. Techniques for reducing heat leak into cryotanks include using passive multi-layer insulation (MLI) and vapor cooled or actively cooled thermal shields. Large scale shields cannot be supported by tank structural supports without heat leak through the supports. Traditional MLI also cannot support shield structural loads, and separate shield support mechanisms add significant heat leak. Quest Thermal Group and Ball Aerospace, with NASA SBIR support, have developed a novel Load Bearing multi-layer insulation (LBMLI) capable of self-supporting thermal shields and providing high thermal performance. We report on the development of LBMLI, including design, modeling and analysis, structural testing via vibe and acoustic loading, calorimeter thermal testing, and Reduced Boil-Off (RBO) testing on NASA large scale cryotanks. LBMLI uses the strength of discrete polymer spacers to control interlayer spacing and support the external load of an actively cooled shield and external MLI. Structural testing at NASA Marshall was performed to beyond maximum launch profiles without failure. LBMLI coupons were thermally tested on calorimeters, with superior performance to traditional MLI on a per layer basis. Thermal and structural tests were performed with LBMLI supporting an actively cooled shield, and comparisons are made to the performance of traditional MLI and thermal shield supports. LBMLI provided a 51% reduction in heat leak per layer over a previously tested traditional MLI with tank standoffs, a 38% reduction in mass, and was advanced to TRL5. Active thermal control using LBMLI and a broad area cooled shield offers significant advantages in total system heat flux, mass and structural robustness for future Reduced Boil-Off and Zero Boil-Off cryogenic missions with durations over a few weeks.