Passive Thermal Control Research Articles

Thermal Design and Experimental Validation of a Lightweight Microsatellite

The multiple working modes, complex working conditions, frequent changes in external heat flux, and high-power consumption of satellites all pose great difficulties to their thermal design. In this paper, the material MB15 magnesium alloy was used, which has not been performed for the main structure of satellites. This material not only reduces the weight of the structure and the launch cost, but also its good thermal conductivity is very helpful for the thermal control design of the satellite. This paper mainly describes the design of a thermal control system for lightweight microsatellites. Firstly, the satellite structure, thermal control indices of the main equipment, and the power consumption of the equipment in different working modes are introduced. Then, the external heat fluxes are analyzed, the position of the heat dissipation surface and extreme conditions are confirmed, and detailed thermal designs of each part of the satellite are determined via the combination of active and passive thermal control. Finally, the thermal balance test is carried out for the whole satellite. It is found that the deviation between the temperature of the thermistor and thermocouple at the same moment in the thermal analysis simulation data and thermal balance test is generally within 0.5 °C, and the maximum difference is not more than 1.7 °C, which indicates that the simulation model is well established and that the thermal analysis is reliable.

Reduced-Graphene-Oxide-Based Thin Films: An Alternative Coating for Harsh Space Environments.

Polymeric materials are commonly used as the outermost layer in spacecraft passive thermal control. However, in geostationary earth orbit environments, the polymeric layer is susceptible to environmental hazards, particularly electrostatic charges. In this study, we develop a graphene-based coating on a polymeric polyimide (Kapton®) and discuss its suitability in simulated harsh space environments for electrostatic dissipation. An about 80-100 nm thick conducting reduced graphene oxide (rGO) coating was developed on Kapton® by a simple and cost-effective spray technique while ensuring minimal variation in the thermo-optical properties and hence the equilibrium temperature. The spaceworthiness and stability of the coating were evaluated through simulated space environment tests, including thermal cycling, thermal vacuum, relative humidity, adhesion, and aging tests. Structural, optical, and electrical properties were found to be preserved after spaceworthiness tests, demonstrating the durability of the coating in harsh space environments. Furthermore, field emission scanning electron microscopy demonstrated significant electron charging on uncoated Kapton®, with a gradual reduction in charge buildup for GO-coated Kapton®, and almost negligible charging on rGO-coated Kapton® when subjected to electron bombardment at 10, 15, and 20 kV. Kelvin probe force microscopy further confirmed the enhanced electrostatic dissipative properties, showing a notable decrease in surface potential from 300 mV for uncoated Kapton® to 60 mV for rGO-coated Kapton®. These findings suggest that the developed graphene-based coating holds promise as a space-survivable solution for electrostatic dissipation in a spacecraft.

Phase-Changeable Metafabric Enables Dynamic Subambient Humidity and Thermal Regulation.

A promising approach to prevent heat- and cold-related illnesses is the integration of zero-energy input control technology into personal thermal management (PTM) systems while reducing energy consumption. However, achieving optimal wearing comfort while maintaining subambient metabolic temperatures using thermally regulating materials without an energy supply remains challenging. In this study, we provide a simple and reliable methodology to produce a phase-changeable metafabric made of thermoplastic polyurethane and phase change capsule (PCC) particles with high moisture permeability and thermal comfort. This approach skillfully incorporates spray-formed PCC particles into a three-dimensional nanofibrous aggregate, forming a stable self-entangled network structure in a single step through simultaneous humidity-assisted electrospraying and electrospinning processes. Additionally, the metafabric demonstrates prominent water resistance and superhydrophobicity, which are attributed to the integration of PCC particles and nanofibers, resulting in the formation of a microporous/nanoporous structure resembling the surface of a lotus leaf. As a result, the phase-changeable metafabric shows an active and passive thermal control performance, with a water vapor transmittance rate of 13.1 kg m-2 d-1 and a phase change enthalpy of 115.05 J g-1 even after 100 thermal cycles. Furthermore, it displays excellent waterproofing capability, characterized by a water contact angle of 158.7° and the ability to withstand a high hydrostatic pressure of 87 kPa. In addition, the metafabric exhibits a good mechanical performance, boasting a tensile strength of 10.5 MPa. Overall, the proposed economical metafabric is an exemplary candidate material for next-generation PTM systems.

Laboratory Experiments on Passive Thermal Control of Space Habitats Using Phase-Change Materials

Here, we investigate the performance of phase-change materials (PCMs) in the passive thermal control of space habitats. PCMs are able to absorb and release large amounts energy in the form of latent heat during their (typically, solid-to-liquid) phase transition, which makes them an ideal choice for passive temperature control. In this study, a conceptual design of an igloo-shaped habitat is proposed. A scaled model for laboratory experiments is manufactured via 3D printing, using tap water as the PCM. The setup is used to conduct experiments and analyze PCM performance, based on temperature measurements inside and outside the habitat. Results demonstrate the effectiveness of PCMs in increasing thermal inertia and stabilizing the habitat interior temperature around the melting temperature, confirming that PCMs can be a suitable alternative for passive thermal control. The present study holds significant interest for the future of space exploration, with the emerging need to design habitats that are capable of accommodating astronauts.

Comparative Study of Active and Passive Thermal Control Systems: A Case Study of Terra Satellite

Comparative Study of Active and Passive Thermal Control Systems: A Case Study of Terra Satellite

Study on temperature noise suppression characteristics of passive thermal control materials in gravitational wave detection

Study on temperature noise suppression characteristics of passive thermal control materials in gravitational wave detection

Thermoelectric energy harvesting associated with heat pipes for monitoring highways weather conditions

This work aims to develop a prototype for autonomously monitoring highway weather conditions using thermoelectric energy. The prototype utilizes solar thermal energy, heat absorbed by the asphalt and soil heat to generate, convert, manage, and store energy. The study investigates the optimal functioning of the thermoelectric generator, including utilizing the soil as a heat sink and incorporating passive thermal control devices like heat pipes. A commercial ultra-low power converter model LTC3108 was experimentally tested for efficient energy conversion. The monitoring system is designed to acquire readings from sensors measuring relevant climate parameters such as temperature, atmospheric pressure, and humidity, focusing on ultra-low power characteristics. The acquired data is transmitted via LoRa technology to a server for processing and analysis. The prototype generated 286.24 J of energy with a maximum temperature gradient of 4.25 ºC in the thermoelectric generator. The energy cost of transmitting a 40-byte message through the LoRaWAN module was 0.625 J. The proposed climate data acquisition circuit had a theoretical consumption of 17.69 J. Experimental tests with the LTC3108 converter, and a 0.22 F supercapacitor demonstrated successful data transmission. This work provides a solid foundation for future studies utilizing thermoelectric energy in highway applications, resulting in a prototype suitable for real-world road scenarios.

Suitable material design of temperature-stabilizing device using phase change materials for electric power supply of nanosatellites

This study proposes a new passive thermal-control device utilizing phase-change materials (PCMs) that require minimal active thermal support, such as heaters, to achieve a high-performance and high-reliability power supply for nanosatellites and other space applications. This study evaluated two different PCMs as candidate materials for the device and compares their performances as thermal control devices. One was a solid–solid PCM based on vanadium dioxide doped with tungsten (VWO2), and the other was a microencapsulated PCM containing n-paraffin (NPH-MPCM). For integration into nanosatellites, it is essential to form a PCM as solid blocks. This report adopted a solidification method using epoxy resin (EP) as the binder and determined the optimal block composition for each PCM. The thermal-insulation properties of both PCM blocks in vacuum and low-temperature environments were evaluated and found to be almost equivalent. Considering that the latent heat of VWO2 is only approximately one-fifth that of NPH-MPCM, the practical application of VWO2 as a PCM was demonstrated. Furthermore, VWO2 exhibits a phase-change temperature hysteresis of 4 °C, which is significantly smaller than the 23 °C of NPH-MPCM. This characteristic is expected to help maintain a more constant temperature for power supplies in earth-orbiting micro/nanosatellites. Moreover, lithium-ion battery cells were incorporated into both VWO2-based and NPH-MPCM-based PCM blocks, and their charge–discharge behaviors were evaluated. Only the VWO2-based PCM block could maintain appropriate temperatures to ensure stable charge–discharge operation. Vacuum resistance results suggested that the VWO2-based PCM block is well-suited as a temperature-stabilizing device for electric power supplies in nanosatellites.

Thermal Control Coatings Flown on Low Earth Orbit Materials Experiments

Coatings developed by AZ Technology were exposed to the space environment on two different platforms and analyzed for optical property changes. These coatings were primarily for passive thermal control, but electrostatic dissipative coatings and marker coatings were also flown. Some materials were flown on the Materials on International Space Station Experiment (MISSE) 15th and 16th flights, and some were flown on the Materials Exposure and Technology Innovation in Space (METIS) first flight. The MISSE and METIS flights were both in low Earth orbit but had very different results. Space environmental and molecular contamination effects on optical properties are reviewed. Future experiments, including the Regolith Adherence Characterization flight to the moon, are discussed.

Solar Heat Flux Suppression on Optical Antenna of Geosynchronous Earth Orbit Satellite-Borne Lasercom Sensor.

The objective of this article is to examine potential techniques for suppressing solar heat flow on the optical antenna of a laser communication sensor. Firstly, the characteristics of the geosynchronous Earth orbit's (GEO) space radiation environment are analysed, and a combined passive and active thermal control solution is proposed. Secondly, the temperature distribution of the lasercom sensor under extreme operating conditions is simulated utilising IDEAS-TMG (6.8 NX Series) software, which employs Monte Carlo and radiative heat transfer numerical calculation methods. Finally, a strategy for avoiding direct sunlight around midnight is proposed. The simulation results demonstrated that the thermal control solution and solar avoidance strategy proposed in this paper achieved long-term fine-stable control of the temperature field of the optical antenna, which met the thermal permissible communication hours per daily orbit cycle in excess of 14 h per day.

Durability of Passive Thermal Control Materials Exposed to Low-Earth-Orbital Environment

Spacecraft components for passive thermal control need to resist degradation in the space environment. The Materials on International Space Station Experiment (MISSE) 11th and 15th flights and the Materials Exposure and Technology Innovation in Space 1st and 2nd flights exposed a variety of materials to the low-Earth-orbital environment. Materials analyzed in this effort include thermal control coatings with ceramic or silicone binders, components for multilayer insulation blankets, and chemical conversion coatings per MIL-DTL-5541. Space environmental and molecular contamination effects on optical properties are reviewed. Future MISSE experiments are discussed.

Passive thermal control design and flight operation results of nano moon lander OMOTENASHI

OMOTENASHI is a 6U CubeSat launched by the first NASA SLS rocket. Its mission was to demonstrate that a CubeSat can make a semi-hard landing on the Moon. Tight resource constraints make it difficult to mount a heater and a radiator in a CubeSat, so passive thermal control is a prominent design feature of OMOTENASHI that resolves the technical difficulty. In November 2019, a thermal vacuum test was conducted. This paper discusses the thermal design and the test results. OMOTENASHI was launched by SLS rocket on November 16, 2022. After the SLS rocket separation, OMOTENASHI's attitude control malfunctioned so it could not generate power from its solar cells. Eventually, communications were lost and have not been restored. Brief telemetry data confirmed that the temperature monitor functioned correctly for 30 min. This paper reports the flight results of the thermal status during the first ground station pass. Also, a comparison between the analysis model and telemetry data is shown. Finally, based on its estimated trajectory, the future thermal profile of the spacecraft and the result of the search operation are discussed.

A generative design framework for passive thermal control with macroscopic metamaterials

Efficient thermal management holds pivotal significance in the rapidly evolving realm of energy-dense applications, notably in high-performance computing, where the push toward miniaturization encounters limitations in controlling heat flux within confined spaces. The advent of metamaterials presents an energy-free opportunity to transform thermal control, essential to boosting system efficiency. This work marks a step toward integrating AI in the design and optimization of compact systems, such as printed circuit boards, solar collectors, and power electronics. We present an automated generative design exploration framework for thermal metamaterials capable of effectively controlling heat transfer to achieve multiple objectives: unperturbed temperature distribution (cloaking) and targeted heat flux insulation and concentration. The architected structures developed leverage the optimization of unit cell arrangements with contrasting thermal properties to exhibit characteristics not commonly occurring in nature. This framework employs a variational autoencoder (VAE), trained on bio-inspired leaf and mushroom microstructures, to assemble bi-material unit cells on a flexible lattice for arbitrary domains. By operating a genetic optimizer within the reduced design space of the VAE, we develop these assemblies to address adversarial temperature and heat flux objectives using a finite element solver. We demonstrate the modularity and scalability of the framework, outputting multi-objective metamaterial solutions for user-specified thermal requirements within a total run-time of 5 min only.

Angle-Resolved Direct Emissivity Measurements on Unencapsulated Solar Cells for Passive Thermal Control

Angle-Resolved Direct Emissivity Measurements on Unencapsulated Solar Cells for Passive Thermal Control

Extendable origami multilayer insulation thermal characterization

Spacecraft commonly use multilayer insulation (MLI) for passive thermal control, however deployable structures such as telescoping booms impose the need to stow MLI preflight and extend with the structure for in flight operation. This paper investigates an octagonal origami folding pattern that allows predictable stowage and extension of multilayer insulation. Feasibility was demonstrated to fold, compress and extend a MLI blanket comprising 10 layers of aluminized Kapton, each separated by a layer of scrim cloth. Both folded and unfolded 10-layer MLI blankets were tested in thermal vacuum to characterize heat leak of deployed configurations. The 10-layer origami folded configuration increased thermal conductance and radiative heat transport relative to the unfolded configuration. Degradation factors for heat transport were empirically found to be Mk=2.5±0.3 and Me=1.3±0.2 for effective thermal conductance and emittance, respectively.

The “Effect of Marangoni Convection on Heat Transfer in Phase Change Materials” experiment: Design and performance of the cuboidal cell

The experiment “Effect of Marangoni Convection on Heat Transfer in Phase Change Materials” aims to investigate the efficacy of thermal Marangoni convection in augmenting the heat transfer rate of passive phase change materials (PCMs) that incorporate a free surface in microgravity; the so-called thermocapillary-enhanced PCMs. Compared to thermal conduction, thermocapillary flows can increase heat transport by a factor of two or more. In addition to advancing scientific understanding, the experiment seeks to evaluate the practical feasibility of using thermocapillary-enhanced PCMs as passive thermal control devices for space missions and assess possible implementation challenges. By analyzing different PCM samples, the experiment will provide crucial insights into the heat and mass transport mechanisms of thermocapillary flows during melting and solidification. The present article primarily describes the design, thermal control and ground results of the cuboidal cell of the experiment. We illustrate here the comprehensive approach towards developing space experiments adhering to rigorous and demanding scientific and technical requirements. Along with the validation of an initial experiment prototype, the evaluation of ground tests is also addressed. The hardware developed demonstrates an adequate performance, while the obtained scientific results are coherent and compliant with the established requirements; the feasibility of the proposed design is thus demonstrated.

Phase-transition materials derived photonic metamaterials for passively dynamic solar thermal and coldness harvesting

The rising need for energy to actively heat and cool human-made structures is contributing to the growing energy crisis and intensifying global warming. Consequently, there's a pressing need for a sustainable approach to temperature management that minimizes energy consumption and carbon emissions. The substantial temperature differences between the Sun (approximately 5800 K), Earth (around 300 K), and outer space (about 3 K) offer a unique opportunity for passive thermal regulation on a global scale. Recent research indicates the possibility of addressing this issue through various low-carbon, passive technologies such as solar heating and radiative cooling. However, their practical application is often limited to certain seasons and climatic regions due to their static and single-function nature in managing temperature. In this context, we introduce a concept of phase-change metamaterials that provide passive, dynamic, and adjustable radiative thermal control, suitable for widespread engineering applications. Our designed metafilm comprises a Polydimethylsiloxane (PDMS) layer infused with vanadium dioxide (VO2) nanoparticles, backed by a layer of broadband-reflective silver (Ag). This metafilm exhibits a self-adjusting solar absorptance, shifting from 0.96 to 0.25 at a pivotal temperature while maintaining a nearly constant thermal emittance. We can finely tune the metafilm's optical characteristics by altering the VO2 nanoparticle concentration and PDMS layer thickness. To demonstrate its efficacy in solar thermal management and radiative cooling, we simulate its temperature behavior under various weather conditions.

The DEPLOY! Project: Development of a Deployable Pulsating Heat Pipe experiment on a parabolic flight

DEPLOY! Project aims at analysing the behaviour of Deployable Pulsating Heat Pipe (PHP) shaped as a helicoidal torsional spring in the adiabatic section on board a Parabolic Flight platform. A PHP is a passive thermal control device where the heat is efficiently transported by means of the self-sustained oscillatory fluid motion driven by the phase change phenomena. The microgravity environment allows to eliminate the buoyancy force contribution in the liquid phase momentum. Consequently, it is possible to isolate the contribution of the pressure drop caused by the 3D arrangement and infer on their effect on the PHP performance. As a result, a proper design based on the previous considerations would increase the flexibility of the PHP for use in space applications without significant reductions in efficiency. The goal of DEPLOY! is to demonstrate the functionality of a Deployable Pulsating Heat Pipe in various unfolding configurations by analysing its thermal-hydraulic response throughout a Parabolic Flight. The presented Deployable PHP is composed of an aluminium tube (inner/outer diameters 1.6mm/2.6 mm) and filled with HFE-7000. It is heated at the evaporator using a flat heater and cooled at the condenser with a water-cooled cold plate. T-type thermocouples are used to measure the wall temperature in several locations, while two pressure transducers (one located in the evaporator section and another in the condenser section of the same pipe) measure the local fluid pressure. Additionally, an IR Camera will be used to observe a section of the pipe for further analysis of the flow frequency. The device operation will be tested on ground and 0-g at different heat loads (24W, 34W), in multiple static positions corresponding to different opening angles (0°, 45°, 90°, 135°, 180°) and during its dynamic opening from 0° to 180°, thanks to a remotely controllable motion system.

System multi-scale analysis of temperature control for spaceborne electronic devices

<sec>To improve the simulation resolution and accuracy in thermal analysis of spaceborne electronic devices and the temperature control performance of passive thermal control devices, a system multi-scale model is established, thereby obtaining the temperature field and heat flux of electronic devices inside the satellite on different scales as illustrated in the below figure. The temperature fluctuation mechanism inside the satellite is analyzed on different physical scales. The thermal analysis resolution of spaceborne electronic equipment is improved, and a method to reduce the power fluctuation of spaceborne equipment is proposed based on the results of system multi-scale thermal analysis.</sec><sec>The results indicate that the accuracy deviation between the multi-scale model of the system and the actual model is less than 9%. However, the system multi-scale model saves 99.67% of the mesh generation time, which greatly improves the computation efficiency. The system multi-scale model can capture the thermal information about device-level chip microstructures at a lower computational cost. The system-level model can evaluate the temperature control and insulation performance of passive thermal control materials on a macroscale. The temperature fluctuation amplitude of the platform compartment is 7.95 K, while the temperature fluctuation amplitude of the load compartment decreases to 2.43 K after the temperature of the composite phase change insulation material has been controlled, which is 69.43% lower than that of the platform compartment. Compared with traditional vacuum insulation panels, the composite phase change materials are very superior in controlling the temperature of the chamber and suppressing temperature fluctuations. The temperature fluctuation signal after being insulated by the composite phase change insulation materials shows a characteristic of shifting to the high-frequency domain. After selecting the cabins that require key insulation and temperature control through multiple regression analysis, a simplified model at device level is employed to obtain temperature fields under different thermal control device layouts as a training dataset. A neural network genetic algorithm is used to predict the optimal installation position of passive thermal control device on the device scale and a thermal control layout scheme is obtained, which reduces the maximum temperature fluctuation of the device by 2.74 K. If the temperature uniformity coefficient is taken as the optimization goal, the temperature of each device on PCB board can be reduced to 14.39% of the average temperature of all devices through optimizations.</sec>

Triangular fin array passively actuated by bimetallic coils for CubeSat thermal control

CubeSat thermal control can be especially demanding due to volume and size constraints, high power dissipation per unit surface area, and highly variable internal and external heat loads. As such, CubeSat developers must rely on thermal control systems that meet the specific requirements of their mission and environmental conditions. Deployable radiators enable satellites to increase their radiative surface area and to reveal highly emissive surfaces during times when increased heat rejection is desired. In colder conditions, when decreased heat loss is preferable, the radiators can be stowed. Passive thermal control systems are unpowered and can increase system reliability by not relying on control electronics while offering decreased weight and power requirements. In this work, we propose a deployable array of triangular radiator panels that are independently and passively actuated by bimetallic coils in response to changes in temperature. This system demonstrates the use of bimetallic coils to passively deploy and stow the radiator fins as well as the use of multiple CubeSat radiator fins with independent actuators to provide increased redundancy. An experimental prototype of the system design was subjected to vacuum chamber testing with panels held in a fixed, deployed position to obtain temperature data used to tune a thermal simulation model. The prototype was then placed in a cryogenically cooled vacuum chamber environment with the panels free to actuate passively in response to varied heating conditions. Both steady state and transient testing were performed. Through this testing and the use of the tuned thermal simulation, the experimental prototype is determined to have a turndown ratio (largest cooling power / smallest cooling power) of 5.4. Deployment of the radiator panels serves to reduce CubeSat body temperatures by 45 °C. Results show the efficacy of the bimetallic coil actuators and radiator fin array in providing passive, dynamic thermal control to small satellites. Recommendations are made to further enhance the performance of the system. Of these recommendations, the most critical is to improve the thermal conductive path from the CubeSat body to the bimetallic coils and to the triangular radiator panels across the deployable radiator hinge. Such changes provide the possibility of increasing the maximum heat rejection, responsiveness of the thermal control system, and turndown ratio to 9 or greater.