Passive intermodulation free multilayer thermal blanket

• US 6,623,826 B2
• Filed: 10/29/2001
• Issued: 09/23/2003
• Est. Priority Date: 10/29/2001
• Status: Expired due to Term

• Current Assignee: Maxar Space LLC (Galileo Parent, Inc.)
• Original Assignee: Space Systems/Loral Incorporated (Loral Space and Communications Incorporated)
• Inventors: Owings, Mary, Hasegawa, Mark
• Primary Examiner(s): Thomas, Alexander S.
• Application Number:
  US10/020,704
• Publication Number:
  US 20030082332A1
• Time in Patent Office: 694 Days
• Field of Search: 428/122, 428/68, 428/44, 428/57, 428/76, 428/138, 244/117.A, 244/158.A
• US Class Current: 428/44
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/20 using fillers, pigments, thixotroping agents
• CPC Class Codes: B64G 1/58 Thermal protection, e.g. heat shields
• CPC Class Codes: Y10T 428/16 Two dimensionally sectional layer
• CPC Class Codes: Y10T 428/19 Sheets or webs edge spliced or joined
• CPC Class Codes: Y10T 428/23 Sheet including cover or casing
• CPC Class Codes: Y10T 428/237 Noninterengaged fibered material encased [e.g., mat, batt, etc.]
• CPC Class Codes: Y10T 428/24198 Channel-shaped edge component [e.g., binding, etc.]
• CPC Class Codes: Y10T 428/24331 including nonapertured component

Abstract

Thermal apparatus that reduces passive intermodulation products generated on a satellite or other spaceborne vehicle. Exemplary passive intermodulation free thermal blankets comprise a reflector stack including multiple polyimide layers with metallized film on one side thereof, a binding layer that secures the reflector stack together, and an outer cover layer that wraps around the binding layer and reflector stack to cover an outer surface of the thermal blanket and form a hem on an inner surface of the thermal blanket. Multiple small thermal blankets or patches may be bound together using grounding inserts and polyimide tape to form a quilt-like assembly. The quilt-like assembly is enclosed by an outer cover layer that wraps around the multiple patches to cover one surface thereof and form a hem on an opposite surface thereof.

Claims

1. Passive intermodulation free thermal blanket apparatus comprising:

a reflector stack comprising multiple polyimide layers having metallized film on one side thereof;

a binding layer that secures the reflector stack together; and

outer cover layers that wrap around the binding layer and reflector stack to cover an outer surface of the thermal blanket and form a hem on an inner surface of the thermal blanket.

2. The thermal blanket recited in claim 1 wherein the metallized film layers are oriented in a single direction so that they do not touch each other.

3. The thermal blanket recited in claim 1 wherein the binding layer comprises layers of polyimide tape, aluminum foil tape with conductive adhesive, and carbon loaded polyimide film.

4. The thermal blanket recited in claim 1 wherein the layers of the reflector stack are perforated to allow for venting of the thermal blanket.

5. The thermal blanket recited in claim 1 wherein the outermost metallized layer of the outer cover layers is non perforated.

6. Passive intermodulation free thermal blanket apparatus comprising:

a reflector stack comprising multiple polyester layers having metallized film on one side thereof;

a binding layer that secures the reflector stack together; and

outer cover layers that wrap around the binding layer and reflector stack to cover an outer surface of the thermal blanket and form a hem on an inner surface of the thermal blanket.

7. The thermal blanket recited in claim 6 wherein the metallized film layers are oriented in a single direction so that they do not touch each other.

8. The thermal blanket recited in claim 6 wherein the binding layer comprises layers of polyimide tape, aluminum foil tape with conductive adhesive, and carbon loaded polyimide film.

9. The thermal blanket recited in claim 6 wherein the layers of the reflector stack are perforated to allow for venting of the thermal blanket.

10. The thermal blanket recited in claim 6 wherein the outermost metallized layer of the outer cover layers is non perforated.

11. Passive intermodulation free thermal blanket apparatus comprising:

a plurality of overlapping passive intermodulation free thermal blanket patches that each comprise a reflector stack comprising multiple polyimide layers having metallized film on one side thereof, a binding layer that secures the reflector stack together, and an outer cover layer that wraps around the binding layer and reflector stack to cover an outer surface of the thermal blanket and form a hem on an inner surface of the thermal blanket;

one or more grounding inserts that contact adjacent overlapping ends of the patches;

a layer of polyimide disposed between the patches to isolate them;

a layer of polyimide that bonds the patches together; and

outer cover layers that wrap around the plurality of patches to cover an outer surface of the thermal blanket apparatus and form a hem on an inner surface of the thermal blanket apparatus.

12. The apparatus recited in claim 11 wherein the metallized film layers are oriented in a single direction so that they do now touch each other.

13. The apparatus recited in claim 11 wherein the binding layer comprises layers of polyimide tape, aluminum foil tape with conductive adhesive, and carbon loaded polyimide film.

14. The apparatus recited in claim 11 wherein the layers of the reflector stack are perforated to allow for venting of the thermal blanket.

15. The apparatus recited in claim 11 wherein the metallized outer cover layer that wraps around the patch binding layer and reflector stack is non perforated.

16. Passive intermodulation free thermal blanket apparatus comprising:

a plurality of overlapping passive intermodulation free thermal blanket patches that each comprise a reflector stack comprising multiple polyester layers having metallized film on one side thereof, a binding layer that secures the reflector stack together, and an outer cover layer that wraps around the binding layer and reflector stack to cover an outer surface of the thermal blanket and form a hem on an inner surface of the thermal blanket;

one or more grounding inserts that contact adjacent overlapping ends of the patches;

a layer of polyimide disposed between the patches to isolate them,

a layer of polyimide that bonds the patches together; and

an outer cover layer that wraps around the plurality of patches to cover an outer surface of the thermal blanket apparatus and form a hem on an inner surface of the thermal blanket apparatus.

17. The apparatus recited in claim 16 wherein the metallized film layers are oriented in a single direction so that they do not touch each other.

18. The apparatus recited in claim 16 wherein the binding layer comprises layers of polyimide tape, aluminum foil tape with conductive adhesive, and carbon loaded polyimide film.

19. The apparatus recited in claim 16 wherein the layers of the reflector stack are perforated to allow for venting of the thermal blanket.

20. The apparatus recited in claim 16 wherein the metallized outer cover layer that wraps around the patch binding layer and reflector stack is nonperforated.