Project Title:

Fluted Core Braiding for Flexible Blanket Insulation Thermal

Foster-Miller, Inc.
350 Second Avenue
Waltham, MA 02154-1196

93-1		04.24	3200			Amount Requested $69.969

Fluted Core Braiding for Flexible Blanket Insulation Thermal 
Protection Systems

Abstract:

Tailorable Advanced Blanket Insulation (TABI) has been developed as 
a thermal protection system for future transatmospheric vehicles.  
TABI is produced in weaving looms at low rates and is very 
expensive.  Foster-Miller proposes an improved textile process for 
TABI.  Two flat braiders simultaneously produce parallel 0@/+0/-0 
triaxial flat fabric facesheets.  The axial (O@) tows run 
alternately through both facesheets via synchronized transfer 
creels.  Crossover of axial tows forms the ribs between the 
facesheets.  Ceramic batting insulation can be incorporated into 
the flutes during braiding.  Due to the inherently faster rate of 
braiding versus weaving, and the elimination of the flute 
"stuffing" operation, this process should lower the cost of TABI.  
Furthermore, Foster-Miller has developed braiding machinery that 
has 25X the fiber capacity of current braiders; thus dramatically 
reducing setup and downtime.  Another advantage of braided TABI is 
that triaxal fabrics are stronger than simple 0/90 wovens.  In 
Phase 1, Foster-Miller will validate the machinery concept to form 
braided fluted core TABI.  The program team includes McDonnell-
Douglas (SSTO program), and an expert in commercialization of 
advanced textiles.  Phase II would involve fabrication of a high 
volume TABI braider and a parallel effort to develop private sector 
applications for TABI.

Braided TABI should be much cheaper than the current woven form.  
This should extend its appeal to industries that are more price 
sensitive than the aerospace industry.  Potential commercial uses 
for TABI include liners for furnaces and other high temperature 
industrial processing equipment, and fire barrier protection 
systems for ships, buildings, and oil derricks.  The Phase I 
program will include a survey of these industries to determine 
volume requirements and cost barriers.

TABI, Thermal Protection Systems, Braiding, Flexible Blanket 
Insulation