Performance Of Multilayer Insulation Research Articles

Validation of heat transfer models and optimization of heat shielding performance of high-temperature multilayer insulations for hypersonic vehicles

Multilayer insulation (MLI) is widely used in hypersonic vehicles because of its low density and excellent thermal insulation performance. However, the insulation mechanism of MLI remains poorly understood, leading to conflicting views on how to enhance its thermal insulation capabilities. In this study, two different numerical models were built and validated with experiment data to investigate key factors influencing MLI performance. The analysis focused on the effects of reflective screen positioning, the surface emissivity of reflective screens and the radiation properties parameters of fibrous materials on the thermal insulation performance of the MLI. The results show that the thermal insulation performance is better when the reflective screens are placed close to the thermal boundary. Moreover, insulation materials with lower absorption coefficients enhance the effectiveness of the reflective screens, further improving the thermal insulation performance of MLI. In addition, the study reveals that the thermal insulation mechanisms differ between the upper and lower surfaces of the reflective screens. Lower emissivity on the upper surface combined with higher emissivity on the lower surface optimizes the thermal insulation performance of MLI. These findings offer valuable insights for advancing MLI designs and improving its application in future high-speed vehicles.

Theoretical analysis of entropy generation in multilayer insulations: A case study of performance optimization of variable density multilayer insulations for liquid hydrogen storage systems

Liquid hydrogen (LH2) is a promising and economical clean energy for achieving global carbon neutrality. Multi-layer insulation (MLI) with high performance is essential for the safe storage and operation of LH2. To perform a better optimization of MLI, the second law of thermodynamics becomes a complement to the first law of thermodynamics. However, very few studies have carried out the optimization of MLI performance through the second law of thermodynamics. For the sake of achieving more efficient optimization of MLI as well as revealing the fundamental indicators limiting the performance of MLI, this paper analyzes the characteristics of entropy generation produced by the solid heat conduction, thermal radiation, and residual gas conduction distributed in the MLI schemes by a validated layer-by-layer model.For a 40-layer MLI arranged with a constant layer density of 20 layers/cm, the first 15 layers near the cold boundary occupy more than 98% of the total entropy generation, providing an effective range of layers for thermodynamic optimization. Besides, an optimization of variable-density MLI (VDMLI) separated into two segments based on the entropy generation minimization is conducted. The optimal VDMLI has substantially lowered the entropy generation from the solid heat conduction but at the cost of increasing the entropy generation from radiation and residual gas conduction. This study provides a reliable optimization method of MLI, which allows the safe storage of clean energy with a low boiling temperature.

Model Based Exploration of Physical Parameters for Liquid Hydrogen System Insulation Performance

Cryogenic Systems require a highly efficient insulation so as to limit the heat ingress and boil-off, which is generally achieved through the use of vacuum combined with an insulated media. The performance of Multi layer Insulation (MLI) will be investigated with detailed thermal models developed to account for all the heat transfer contributions, solid conduction, gaseous conduction and radiation. Results are presented for an usual cold vacuum pressure (CVP) corresponding to high vacuum (<10−6 torr) and compared with available experimental measurements for state of the art technologies. The nominal thermal performances are then evaluated for a cold temperature of 20K (representative of liquid hydrogen storage temperature), for a degraded CVP with hydrogen and nitrogen as residual gasses and for increased hot boundary temperatures. Other parameters are also discussed such as, the number of layers, material, layers density, venting options, assembly process and material optical properties. Finally, a sensitivity of the thermal performance is also presented with a pressure gradient through the insulation thickness, that could be induced by cryopumping, materials outgassing, pumping times or small leakages.

Calculation and analysis of optimal layer density for variable density multilayer insulation based on layer by layer model and Lockheed equation

The extremely high energy density and carbon-free characteristics of liquid hydrogen (LH2) make it suitable for replacing liquefied natural gas (LNG) as a future energy commodity. However, the extremely low evaporation temperature of LH2 results in high heat leakage. Multilayer insulation (MLI), which is the most thermally efficient insulation system known, is widely used in the fields of hydrogen energy, aerospace, and other cryogenic fields. Variable density multilayer insulation (VDMLI), which has emerged in the last two decades, has improved the performance of MLI by adding spacers to change the density of MLI. However, there has been no significant progress in the optimization theory for VDMLI. In this paper, based on the layer by layer model and the Lockheed equation, a generalized optimal layer density calculation model for VDMLI is established by considering the influences of spacers, compressive pressure, gas pressure, etc. The results indicate that compared to general VDMLI and MLI on liquid hydrogen tanks, the optimal layer density VDMLI (OVDMLI) can reduce heat leakage by 21.1% and 25.3%, respectively. After comparison and analysis, the characteristics and reasons for temperature and heat transfer conductivity profiles of MLI, VDMLI, and OVDMLI are pointed out. The effect of the spacer number on heat flux and spacer profile is analyzed. Additionally, gas pressure profile and heat transfer are investigated with consideration given to the vacuum degree at both boundaries.

Performance of high-temperature lightweight multilayer insulations

Multilayer insulation (MLI) is a kind of high-temperature insulation which employs multiple high-reflective screens to retard the radiation heat, but analyzing and optimizing its heat transfer characteristics by experimental and theoretical models remains low-efficiency and non-visualization. In this work, finite element analysis (FEA) models verified by comparing the simulation and experiment results are established to systematically reveal the numerous and complex effect factors, including the number of layers, thermal boundary, fibrous insulation density and emissivity of reflective screens. The results show that the top temperature of MLIs can be reduced by increasing the number and the emissivity of reflective screens, and the density of fibrous insulation, but there is a reasonable number of layers to achieve the best comprehensive performance of MLI. In addition, the proportion of radiative heat transfer in the total heat transfer increases with increasing heating temperature. The feasibility of optimizing thermal insulation performance based on the FEA models is confirmed by designing the MLIs with stainless steel and aluminum as reflective screens. And the results indicate that the FEA methods can significantly reduce the number of trials and realize the optimal design of MLI.

The temperature model of the thermal re-radiation model in multilayer insulation systems

Abstract In this manuscript, the temperature model of multilayer insulation (MLI) on a spacecraft solar panel in thermal radiation is considered. The thermal insulation performance of MLI and the stress of the spacecraft are also considered. The thermal equilibrium equation of the surface temperature of MLI spacecraft in the presence of current transfer, and the iterative temperature acquisition algorithm of the front and back surface of solar panel MLI are derived. The Gaussian elimination method is used to invert the high order sparse matrix composed of error coefficients, thus realizing the real-time calculation of thermal re-radiation(TRR). The thermodynamic model was applied to the motion simulation of GPS Block IIR satellites, and the theoretical model was verified based on the actual temperature measurement data of several GPS Block IIR satellites. The simulation results have certain reference value for studying the thermodynamic modeling of MLI spacecraft and TRR perturbation calculation.

Qualification of a vertical cryostat for MLI performances tests between 20 K and 60 K to 4.2 K

Boil-off calorimetric measurements of Multilayer Insulation (MLI) performance from 20 K-60 K to 4.2 K are being performed at CERN, extending the range of measurements of MLI to cover cryostat applications where thermal shields are operated at lower temperatures than that of LN2. Possible applications include future large accelerators like the Future Circular Collider (FCC). The tests are carried out in an existing vertical test cryostat shielded with a liquid nitrogen cooled vessel and with an inner cylindrical liquid helium tank carrying the wrapped MLI sample. The cryostat has been modified to insert an additional intermediate thermal shield maintained at controlled temperatures in the 20 K-60 K range, by means of regulated power input from an electrical heater. This paper describes the test cryostat and the MLI performance measurement methodology as well as experimental results of the commissioning and calibration of the instrument.

Thermal performance of multilayer insulation: A review

A multilayer insulation (MLI) is a passive thermal protection system used in cryogenics and space exploration programs as a thermal insulator. It is very thin and light weight. Due to less weight and higher thermal performance of MLI, it found application in space programs to store cryogenic liquid propellant. The effective thermal conductivity of MLI is in the order of 10−5 W/mK. The prediction of heat transfer in MLI is very complex due to the anisotropic conductivity and combination of radiation, gas conduction and solid conduction modes of heat transfer. This work is an attempt to gather some significant research outcome in MLI performance prediction and the factors to be considered while modeling the MLI.

Repeatability Measurements of Apparent Thermal Conductivity of Multilayer Insulation (MLI)

This report presents and discusses the results of repeatability experiments gathered from the multi-layer insulation thermal conductivity experiment (MIKE) for the measurement of the apparent thermal conductivity of multi-layer insulation (MLI) at variable boundary temperatures. Our apparatus uses a calibrated thermal link between the lower temperature shield of a concentric cylinder insulation assembly and the cold head of a cryocooler to measure the heat leak. In addition, thermocouple readings are taken in-between the MLI layers. These measurements are part of a multi-phase NASA-Yetispace-FSU collaboration to better understand the repeatability of thermal conductivity measurements of MLI. NASA provided five 25 layer coupons and requested boundary temperatures of 20 K and 300 K. Yetispace provided ten 12-layer coupons and requested boundary temperatures of 77 K and 293 K. Test conditions must be met for a duration of four hours at a steady state variance of less than 0.1 K/hr on both cylinders. Temperatures from three Cernox® temperature sensors on each of the two cylinders are averaged to determine the boundary temperatures. A high vacuum, less than 10-5 torr, is maintained for the duration of testing. Layer density varied from 17.98 – 26.36 layers/cm for Yetispace coupons and 13.05 – 17.45 layers/cm for the NASA coupons. The average measured heat load for the Yetispace coupons was 2.40 W for phase-one and 2.92 W for phase-two. The average measured heat load for the NASA coupons was 1.10 W. This suggests there is still unknown variance of MLI performance. It has been concluded, variations in the insulation installation heavy effect the apparent thermal conductivity and are not solely dependent on layer density.

Experimental study on heat transfer through a few layers of multilayer insulation from 300 K to 4.2 K

The final focusing magnet system at the SuperKEKB interaction region has been designed under stringent space constraints and consists of 8 main Superconducting (SC) quadrupole magnets, 4 compensation SC solenoids, and 43 SC correction coils. SC correction coils are directly wound on the inner containment tubes of liquid helium (LHe) vessels, which serve as support bobbins for SC cables. Beam pipes, which are kept at room temperature (∼300 K), are inserted into the cold bores of the vessel inner tubes. Between them, the minimal radial gaps are only 3.5 mm. Heat transfer from the warm beam pipes causes the raised operation temperatures of SC cables and increases heat leaks into cryostats. Multilayer insulation (MLI) is adopted to reduce heat flux in the narrow gaps. MLI performance as a function of the layer number was studied with a vertical anti-cryostat of dedicated design. The measurements were carried out by a calorimeter of thermal conduction and a modified LHe boil-off method. This paper presents the cryogenic measurement system and discusses the experimental results for the cryostats of the SuperKEKB final focusing SC magnets.

多層断熱技術Ⅱ

The calorimeter is used to test the thermal performance of multilayer insulation (MLI). The data obtained by the calorimeter installed in a laboratory must be utilized to estimate the thermal performance of MLI fabricated in the actual cryostat for superconducting magnets or the storage vessel for low-temperature liquefied gas. If MLI is fabricated in an actual cryostat so as to be in the state of self-compression, the non-dimensional parameter P* of the compression pressure between the adjacent layers plays an important role as an experimental condition. In order to design a calorimeter, it is necessary to pay attention to its apparent thermal conductivity, which is lowest among all insulation materials and has extremely large anisotropy. In view of this, the MLI sample must be fabricated so that it covers the entire surface of the calorimeter test cylinder, and the cross-section of MLI at its ends must not be exposed to hot surfaces or shield plates. Some amount of distortion or small steps on the cold surface where the MLI is wrapped may cause wrinkles in the MLI; at which time it becomes impossible to determine the value of P*. A new calorimeter utilizing a small cryo-cooler and heat-flow meter is shown. This calorimeter is expected to enable to allow experiments to proceed efficiently by eliminating the burden of handling liquefied gases, like liquid helium.

Influence of tailored MLI for complex surface geometries on heat transfer

Complex, non-developable surfaces require a tailored multi-layer insulation (MLI) for lowest heat load. The most experiments showing the heat transfer through MLI are performed under quasi-ideal conditions determining the principle insulation quality. But the surface to be insulated in real cryostats implies feed-throughs and other non-developable surface parts. The thermal performance of MLI is degraded significantly at cutting points. To investigate this degrading effect a LN2-filled cylinder with a diameter of 219 mm and a length of 1820 mm was insulated with MLI and the heat load was measured by means of calorimetry. In addition the heat load to an insulated cylinder with eighteen branches was measured. Both cylinders have the same surface of 1.37 m2 for a comparison of the results. This article describes the experiments with different ways of tailoring the MLI for the cylinder with branches and discusses their results. It was shown that the cutting points at the branches have a significant degrading influence on the thermal performance of MLI.

Modeling Transmission Effects on Multilayer Insulation

Multilayer insulation (MLI), commonly used in cryogenics, is typically composed of many layers of thin polymer sheets each coated with a thin film of highly reflective metal. The primary purpose of this insulation is to block radiative energy transfer. However, at very low temperatures where blackbody radiation occurs at long wavelengths, some energy may be transmitted through these layers, degrading the performance of the insulation. Traditional modeling techniques assume that the films are opaque and are not easily extended to include radiative transmission through the layers. In order to model the effect of wavelength dependent transmission on the thermal performance of MLI, an L1-norm energy vector is defined and combined with a square energy distribution matrix. The key here is that the energy distribution matrix describes one time step of the radiation—one set of reflections, transmissions, and absorptions—and since this matrix is square, it can be easily raised to a large power, describing the final state of the system quickly. This approach removes the need to track every reflected and transmitted radiation element, but instead determines the eventual location where the thermal radiation energy is deposited. This method can be generalized to model dependence of the reflection and transmission of the radiation on wavelength or angle of propagation, to include thermal conduction effects, and to model transient behavior. The results of this work predict the degree of transmission dependent degradation expected to be seen when using state-of-the-art MLI in low temperature cryogenic systems.

Wrapped multilayer insulation design and testing

New vehicles need improved cryogenic propellant storage and transfer capabilities for long duration missions. Multilayer insulation (MLI) for cryogenic propellant feedlines is much less effective than MLI tank insulation, with heat leak into spiral wrapped MLI on pipes 3–10 times higher than conventional tank MLI. Better insulation for cryogenic feed lines is an important enabling technology that could help NASA reach cryogenic propellant storage and transfer requirements. Improved insulation for Ground Support Equipment could reduce cryogen losses during launch vehicle loading. Wrapped-MLI (WMLI) is a high performance multilayer insulation using innovative discrete spacer technology specifically designed for cryogenic transfer lines and Vacuum Jacketed Pipe (VJP) to reduce heat flux.The poor performance of traditional MLI wrapped on feed lines is due in part to compression of the MLI layers, with increased interlayer contact and heat conduction. WMLI uses discrete spacers that maintain precise layer spacing, with a unique design to reduce heat leak. A Triple Orthogonal Disk spacer was engineered to minimize contact area/length ratio and reduce solid heat conduction for use in concentric MLI configurations.A new insulation, WMLI, was developed and tested. Novel polymer spacers were designed, analyzed and fabricated; different installation techniques were examined; and rapid prototype nested shell components to speed installation on real world piping were designed and tested. Prototypes were installed on tubing set test fixtures and heat flux measured via calorimetry. WMLI offered superior performance to traditional MLI installed on cryogenic pipe, with 2.2W/m2 heat flux compared to 26.6W/m2 for traditional spiral wrapped MLI (5 layers, 77–295K). WMLI as inner insulation in VJP can offer heat leaks as low as 0.09W/m, compared to industry standard products with 0.31W/m. WMLI could enable improved spacecraft cryogenic feedlines and industrial hot/cold transfer lines.

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

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.

A calorimeter for multilayer insulation (MLI) performance measurements at variable temperature

Here we describe a concentric cylindrical calorimeter with radiation guards developed to measure the thermal performance of multilayer insulation (MLI) for low temperature applications. One unique feature of this calorimeter is its ability to independently control the boundary temperatures between room temperature and about 15K using two single-stage Gifford–McMahon cryocoolers. Also, unlike the existing calorimeters that use the evaporation rate of a liquid cryogen to measure the heat load, in the present system the total heat transfer through the MLI is measured by recording the temperature difference across a calibrated heat load support rod that connects the cold inner cylinder to the lower temperature cryocooler. This design allows the continuous mapping of MLI performance over a much wider temperature range with independently controlled boundary conditions. The calorimeter is also suitable for performing a variety of radiation heat transfer experiments including the determination of the temperature dependence of the total emissivity.

Performance of multilayer insulation with slotted shield

Thermal and evacuating performance can be improved by means of slotting a number of one dimension slots on reflection shields of the multilayer insulation (MLI). The influence of slots on thermal radiation and gas conduction heat fluxes are theoretically studied. Based on the analysis and test, the optimum slot rate and length have been obtained. Experiments also show that the performance of MLI with slotted shield will be further improved if a combination of slotted shields with different slot rate can be used to fit the interstitial pressure distribution.

Experimental investigations of multilayer insulation

Multilayer insulation (MLI), using alternate layers of shield and spacer in high vacuum, is the most effective cryogenic insulation developed to date. Due to unpredictable changes in parameters such as winding pressure, uniform contact pressure and interstitial pressure, accurate theoretical prediction of MLI performance is very difficult. Thus, an experimental investigation has been carried out on a few indigenous MLI materials. The investigations are centred on the influence of the number of layers and layer density, with the cold boundary at the same temperature as liquid nitrogen. The experiments have been carried out using a cylindrical vessel with guard vessels on the top and bottom flat surfaces. The interstitial pressure, which depends on conditions pertaining to specific parameters, such as outgassing rate of materials, cryopumping speed and time for evacuation, has also been measured. The results are compared with those obtained from a theoretical analysis carried out for the same combination of shield and spacer materials.