A study was conducted to provide a tailorable advanced blanket insulation based on a woven design having an integrally woven core structure. A highly pure quartz yarn was selected for weaving and the cells formed were filled with a microquartz felt insulation

Pusch, R. H.

English

NASA Technical Reports Server

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NASA CONTRACTOR REPORT 166367 
Thermil"Insu1ation Blanket Material 
R. H. ··.PuseH" 
Wovenl.Sttuclures 
CONTRACT~NAS2-ll a 9 4 
June 198z '. 
NI\5I\ 
1111111111111 1111 11111 11111 11111 11111 11111111 
NF02626 
NASA_CR-166367 
19820022621 
LIBRARY COpy 
LANGLEY RESEt,Rr.t-< ,:;ENTER 
LIBRARY, NASA 
HAMPTON, VIRGINIA 
https://ntrs.nasa.gov/search.jsp?R=19820022621 2020-03-21T07:44:49+00:00Z
NASA CONTRACTOR REPORT 166367 
Thermal Insulation Blanket Material 
R. H. Pusch 
Woven Structures 
Division of Hitco 
Compton, CA 90220 
Prepared for 
Ames Research Center 
under Contract NAS2-11094 
NI\S/\ 
National Aeronautics and 
Space Administration 
Ames Research Center 
Moffett Reid. California 94035 
---' 
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:;;M.. Woven Structures divilion of HITCO Page 1 
THERMAL INSULATION BLANKET MATERIAL 
1.0 INTRODUCTION 
The specific objective of this program was to provide NASA with improved 
advanced flexible reusable surface insulation materials for future Space 
Shuttle flights. A current flexible ceramic blanket, presently under 
final development, relies on a quartz thread to hold the "ceramic 
sandwich" -- like structure together. The need for this thread may be 
eliminated by weaving a continuous fluted thread core quartz fabric that 
forms an integrally woven core. 
2.0 SCOPE 
The program plan was for Woven Structures, a division of HITeO, subsidiary 
of ARMCO. Inc. to weave three different cell size Hitco~ panels using 
quartz yarn and to fill the cells of the Hitcore with Q.Fel~ insulation. 
The fabric width was to be 26 inches and two linear yards each of the 
three cell sizes were to be produced. The three panels were to be the 
following sizes: 
1) 1/2" cell height x 3/4" cell width x 26" wide x 2 yards 
2) 1" cell height xl" cell width x 26" wide x 2 yards 
3) l~" cell height x l~" cell width x 26" wide x 2 yards 
All panels produced were to be heat cleaned at 8500 F for a mini'mum of 
four hours. 
3.0 MATERIALS 
The quartz yarn selected for weaving was Alphaquart~ type 300-2/4-QS7 
having a starch-oil binder and was Obtained on special order f~ 
A.A. I. Products I Inc. ", 
• :L 
4.0 
4.1 
4.1.1 
' .. 
The Q-Felt purchased from'Johns .. Manville Corp. was the,six pounds, per 
cubic foot densitymaterial obtained in standard sheets It''' x: 36:" x 601' •• 
PROCEDURE 
Weaving Development 
The initial setup and debugging of the 48 inch C&K 100m was done using 
fiberglass yarn as a means of conserving the loss of expensive quartz 
yarn. It was during this initial work that it was discovered that the 
100m had a bent crankshaft. making it impossible to control the cell 
dimensions. The entire setup was then moved to another 100m of the 
same type and development work resumed. At this time a new fabric roll 
was also installed. 
Hitcore® 
Q-Fe1t® 
Alphaquartz® 
Trademark for HITeO 
Trademark for Johns-Manville Corp. 
Trademark for A.A.I. Products. Inc. 
~.' • ;~.', 'i-
• 'i..'~.~ .• 
... .. 
. ;.p.:r~ Woven Structures division of HITCO Page 2 
4.1.2 
4.1..3 
4.1.4 
4.1. 5 
4.1.6 
4.1. 7 
4.2 
4.2.1 
4.2.2 
The three pattern chains were designed and made up to be used for pro-
gramming the loom for the three different cell sizes required. The 
chains were installed and glass Hitcore was woven in ~II x 3/4 11 X III X Ill, 
and 1~1I x 1~1I cell sizes. 
A mechanical problem was encountered when the 1" x III cell size glass 
Hitcore weaving was started. It was found that the loom clutch assembly 
was slipping under maximum load in one portion of the weaving sequence 
causing some breakage of warp yarns. This problem was alleviated by 
adjusting the clutch and installing a two horsepower motor to replace 
the original one and one half horsepower motor. Additional adjustments 
to the rollers on the front of the loom, changing the yarn tensioning 
system, and changing the 100m program sequence also were done to minimize 
yarn breakage. 
Three sets of mahogany inspection mandrels were obtained to be used in 
checking the cell size of all fabric produced. The glass Hitcore produced 
was then checked and found to be satisfactory in size and weave pattern. 
After debugging the loom and making cell size adjustments using fiber-
glass yarn, the creel was reloaded with quartz yarn. The quartz yarn 
was tied on to the glass yarn and pulled through the loom. Weaving 
was now initiated using all quartz yarn and the pattern chain for 
1/2" x 3/4" cell size. 
When the loom was operated weaving quartz, considerable warp yarn breakage 
was again encountered. To solve the breakage problem this time, it was 
only necessary to reduce the tension 1n the warp sheets weaving the 
vertical ribs of the core. Following this adjustment, a short length 
of fabric was woven, checked for cell dimensions, and found to be acceptable. 
Production weaving of the quartz Hitcore was then started. Approximately 
four yards of each cell size Hitcore were woven. The individual pieces 
of fabric were checked for cell size confonnity using the wooden inspec-
tion mandrels. Weaving anomalies and cell irregularities were marked 
so that the production panels could be cut out of minimum defect fabric. 
Q-Felt Insertion Development· 
The procedure developed for inserting the Q-Felt into the cells of the 
Hitcore utilized a moistening and freezing technique. 
Pieces of one half inch thick 6 pound per cubic foot density Q-Felt 
were cut, moistened with deionized water, and plied as necessary to 
make panels 1/2, 1, and 1 1/2 inches thick. The wet Q-Felt was covered 
with 3 mil mylar plastic sheet and compressed to the required thickness 
using a fixture having adjustable flat plates. The entire assemblies 
were put into a freezer operating at 50 F for 15 hours. 
.,.. ... 
~Ji¥ Wuven Structures divilion of HITCO Page 3 
4.2.3 
4.2.4 
4.2.5 
4.2.6 
4.2.7 
4.2.8 
4.2.9 
5.0 
After freezing, the panels were cut into strips of appropriate width 
for each cell size. The 1/2 inch thick panels were cut first using 
a large band saw that previously had been cleaned inside and out with 
alcohol. 
The quartz Hitcore panel of 1/2 by 3/4 inch cell size was stuffed with 
frozen strips and put into an oven drying cycle of 3000 F for two hours. 
Following drying, the Hit80re panel was heat cleaned in a cam controlled 
oven having a hold at 850 for 4 1/2 hours. 
After heat cleaning the first panel, it was noticed that a light brown 
discoloration was present in certain areas of the material. 
Some of this discoloration came from water washing off the inside of 
the band saw and depositing dirt on the Q-Felt. 
To alleviate the discoloration problem, the second set of frozen Q-Felt 
panels were cut on a table saw having a chrome plated blade. This 
technique was used on all subsequent panel cutting. 
Further testing on small samples indicated that the residual discolor-
ation was actually incompletely removed starch-oil sizing that had 
carbonized. It was found that the combination of the wet Q-Felt and 
the starch-oil sized quartz when put through the standard drying and 
heat cleaning cycles resulted in some of the starch-oil Sizing being 
"locked" into the surface of the quartz as carbon which is very 
difficult to remove. 
A solution to the discoloration problem was to heat clean the quartz 
fabric before filling the cells with frozen Q-Felt and then simply 
drying the fabric afterwards. This technique resulted in clean white 
fabric having no contamination. 
MATERIALS SHIPPED 
The following materials were supplied to NASA as part of this program: 
1) Quartz Hitcore Panel, Q-Felt Filled, 112M x 3/4" X 26" x 2 yards 
2) Quartz Hitcore Panel, Q-Felt Filled, 1" x I" x 26" x 2 yards 
3) Quartz Hitcore Panel, Q-Felt Filled, l~" x l~" X 26" x 2 yards 
4) Quartz Hi tcore Fabri c. 1/2" X 3/4" x 26" x 36", grey goods 
5) Quartz Hitcore Fabric, 1" x 1" x 26" X 36", grey goods 
6} Quartz Hitcore Fabric, 1~" x 1~:i" X 26" x 36", grey goods 
7) Fiberglass Hitcare Fabric. Style 322. 1/2" x 48" x 36", Volan finish 
... .. 
::;p.¥ Woven Structures divi.ion of HITCO Page 4 
6.0 APPENDIX 
The following attachments are included: 
I} A typical diagram of a woven Hitcore fabric. 
2} A.A.I. Products, Inc. data sheet, IIProperties of Alphaquartzll. 
3) Alphaquartz yarn certification. 
4) Q-Felt certification. 
54 5 
I 
56 1 1 • 11 
FIBERGLAS FLUTED CORE FA»PJCS 
INTEGRALLY-WOVEN CORE MATERIALS 
Woven Structures 
20 21 24 32 35 l6 45 
I I I I 
1 . I 
II 21 22 .25 21 29 30 3l 34 47 
49 SO 53 
I 
• 
• 
48 51 52 55 56 ., 
Properties of ALPHAQUARTZ 
Fiber Properties 
Tensile Strength, P.S. I. @ 750°F, Dia. 8.0 microns 
@ 1000"F, Dia. 7.5 microns 
@ 14oo°F, Dia. 7.4 mIcrons 
Thermal Properties 
Av'g Coeff. of Unear Expansion, 1°C (Temp. range 0-18S2"C) 
SpecIfic Heat, Av'g O-SOO"C, cal/gm·C 
Thermal Conductivity, K @ 20·C C.G.S., cal/sec/cm/cm2l"C 
Softening Point 
Annealing Point 
Strain POInt 
Mechanical Properties 
SpecIfic GravIty 
Hardness Mohs scale 
POIsson CoeffiCIent 
Young's Modulus, p.s.i. 
Typical Laminate Properties 
Flexural Strength, p.s.i. 
TensIle Strength, p.s.i. 
Electrical Properties 
Power Factor, 1 mc at 68°F 
Loss Factor. 1 mc at 68°F 
Dielectric Constant, 68°F 
Volume ResIstivity. ohm/cm al 39O"F 
Composition: 
126,000 
133,000 
99,200 
0.54xl0- S 
0.230 
0.003 
3032"F 
2084°F 
1958°F 
2.2 
5.6 
0,17 
10xle-
77,000 
59,000 
0.0001 
0.0002 
3.7 
lOll 
Si02 > 99.9%; 80ron < SOppm; Alkali Metals (Na, K. U. calculated as Na equivalent) 
< 5Oppm; AI < lS0ppm; Other impurities < 100ppm. 
Above IIgu/lls ate lor blnder·lree ALPHAQUARTZ. Coupling agenlS ate normally applteo dunng 
orawlng 10 Improve phySIcal charaClansllCS oIlamlnalas. Average pIckup - <: 5°'. by welghl 
A.A. I. Products Inc. Two Amboy Avenue. Woodbridge. New Jersey 07095 (201) 634-5700 Telex #13-8024 
) 
A. A.1. PRODUCTS, INC. 
TWO AMBOY AVENUE. WOODBRIDGE. N. J. 07095 (201) 634 .. 5700 
CERTIFICATION 
PRODUCT: Alphaquartz Yarn 
TYPE: Style 300-2/4-QS7 
LOT NO.: 777 
NUMBER OF 
BOXES: 3 
NUMBER OF 
SPOOLS: 27 
NET WEIGHT: 61.2 1bs. 
SILICA CONTENT: 99.96% 
BINDER 
COMPOSITION: 2.8% 
December 17, 1981 
WOVEN STRUCTURES 
P • O. * ~<JS 5111 
ORDER COMPLETE 
TELEX NO. 
13B·024 
Steramine CGL, 5.0% Sopralube ACR 265, 2.0% So1vitose N 
This is to certify that the A1phaquartz Yarn 300-2/4-Q57 meets the 
requirements of Woven Structure's Specification iMS-0101, 
Revision A, dated September 28, 1977, for the following paragraphs: 
Para. 2.72 and Para. 2.82. 
&-1& 11 t1~ rf= v~ctor G. Penotti &C 
Supervisor, Quality Control 
I L 
'r 
Johns-Manville 
Sales Corporation 
Walarville. Ohio 
(419) 818·8111 
Mailing Address: 
p, 0, Box 517 
Toledo. Ohio 43693 
October 15, 1981 
Woven Structures 
Div. of Hitco 
618 W. Carob Street 
Compton, CA 90220 
Gentlemen: 
This is to certify that J-H's standard inspection 
procedure has been used in the inspection of the 
material covered by this order. This inspection 
indicates that the material tested for J-M Order 
No. G92 ZK 00709, your Order No. WS 5112 complies 
with the applicable finished product requirements 
of Johns-Manville. 
Very truly yours, 
00) ~i. ~---,6 
R. jJ ~anski 
Quality Control.Manager 
" 
Certified in triplicate 
1. Report No. I 2. Government AccIsIion No. 3. Recipient's Catalog No. 
NASA CR-166367 
4. TItle and Subtitle 5. Report Date 
Thermal Insulation Blanket Material June 1982 
6. l'IIrforming Organization Code 
7. Author(s' 8. Performing Or9llnization Report No. 
R. H. Pusch 
10. Work Unit No. 
9. Performin9 Organization Name and Address T-4203 
Woven Structures 11. ContnlCt or Grant No. Div. of Hitco 
Compton, CA 90220 NAS2-ll094 
13. Type of Repon and Period Covered 
12. Sponsoring Agency Name and Address Contractor Final Report 
National Aeronautics and Space Administration 14. Sponsoring Agency Code 
Washington, DC 20546 503-53-31 
15. Supplementary Notes 
Technical Monitor: Paul M. Sawko, M/S 234-1, NASA Ames Research Center, 
Moffett Field, CA 94035 (415) 965-6079, FTS 448-6079 
16. Abstract 
A study was conducted to provide a tailorable advanced blanket 
insulation based ona 3-D woven design using an integrally woven core 
structure. A high purity quartz yarn was selected for weaving and the 
cells formed were filled with a microquartz felt insulation. Three 
panels were provided: 
l. 1/2" cell height x 3/4" cell width x 26" wide x 2 yards 
2. 1" cell height x 1" cell width x 26" wide x 2 yards 
3. 1 1/2" cell height x 1 1/2" cell width x 26" wide x 2 yards 
17. Key Words (Suggested by Author(sll 18. Distribution Statement 
Blanket Insulation Unclassified - Unlimited Quartz Yard 
Microquartz Felt SUBJECT Category - 34 
19. Security C.ssif. (ofthisreportl 120. Security Cblssif. (of this pegIIl 1 21 . NO.
9
0f Pages 122. Price· 
Unclassified Unclassified 
·For sale by the National Technical Information Service, Springfield, Virginia 22161 
End of Document 


Thermal insulation blanket material

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