Method for molding planar billet of thermally insulative material into predetermined non-planar shape

US5705012A · kind A · utility

Assignee

• The United States of America as represented by the Administrator of the National Aeronautics and Space Administration · US

Inventors

• Paul Kolodziej · Redwood City, US
• Joe A. Carroll · Chula Vista, US
• Dane Smith · Greers Ferry, US

Key dates

• Filing date: Apr 22, 1996
• Grant date: Jan 6, 1998
• Expiry date: Apr 22, 2016

Classification

• Technology area (CPC B): Performing Operations; Transporting
• CPC primary: B64G1/58
• WIPO field: Transport
• WIPO sector: Mechanical engineering

Abstract

A method and apparatus for molding thermal protection system (TPS) tiles for spacecraft includes a bottom mold member defining a mold surface shaped like a surface of the spacecraft, e.g., the nose cap or wing leading edge, sought to be thermally protected. A flat billet of TPS material is positioned over the periphery of the mold surface, and a hollow weight element that has a periphery configured like the periphery of the mold surface is positioned on the billet. The billet is then heated in accordance with a predetermined heating regime, and during the heating process the weight of the weight element causes the billet to deform to assume the shape of the mold surface. If desired, a TUFI coating is impregnated into the billet prior to heating, and the coating is sintered to the billet during heating. After heating, a composite matrix material, e.g., a graphite or fiberglass cloth which is impregnated with epoxy or polimide, is bonded to the now-shaped tile to support the tile. Silicone can then be impregnated into the now-formed tile to provide flexibility of the tile.