Rocket assembly ablative materials formed from, as a precursor, staple cellulosic fibers, and method of insulating or thermally protecting a rocket assembly with the same

Abstract

A rocket motor assembly is insulated or thermally protected with a rocket motor ablative material formed from a prepreg. The prepreg contains at least an impregnating resin matrix and, as a precursor prior to carbonization, carded and spun staple cellulosic fibers. When patterned and carbonized, the rocket motor ablative material can be lined or otherwise placed into a rocket motor assembly, such as between the solid propellant and case, in the bulk area of the exit nozzle liner, or at susceptible portions of a re-entry vehicle, such as the nose cone.

1. A method for insulating or thermally protecting a rocket motor assembly comprising a rocket motor casing containing a solid propellant, and a nozzle assembly coupled to the rocket motor casing, said process comprising (a) forming a rocket motor insulation from a prepreg comprising at least one resin matrix impregnated into a carbonized reinforcement, the carbonized reinforcement being formed from, as a precursor prior to carbonization, carded and yarn-spun staple cellulosic fibers and (b) insulating a portion of the rocket motor assembly with the rocket motor ablative material. 
     
     
       2. The process of  claim 1 , wherein the staple cellulosic fibers comprise non-solvent-spun rayon fibers. 
     
     
       3. The process of  claim 2 , wherein the non-solvent-spun rayon fibers have an average length in a range of from 38 mm to 225 mm, and are spun into yarn having a denier per fiber in a range of from 1.5 dpf to 9.0 dpf. 
     
     
       4. The process of  claim 1 , wherein the staple cellulosic fibers are formed from a cellulose-derivative. 
     
     
       5. The process of  claim 1 , wherein the staple cellulosic fibers are untreated. 
     
     
       6. The process of  claim 1 , wherein said insulating comprises applying the rocket motor ablative material between the solid propellant and the casing surrounding the solid propellant. 
     
     
       7. The process of  claim 1 , wherein said insulating comprises applying the ablative material as a bulk ablative material of an exit nozzle liner. 
     
     
       8. The process of  claim 1 , wherein said insulating comprises applying the ablative material as a bulk ablative material of a reentry vehicle nose cone. 
     
     
       9. The process of  claim 1 , further comprising carbonizing the prepreg at at least 1350° C. 
     
     
       10. The process of  claim 1 , wherein the prepreg comprises 31.0-36.0 wt % phenolic resin, 13.0-17.5 wt % carbon black filler, and 46.5 to 56.0 wt % carbon fabric. 
     
     
       11. Rocket motor insulation comprising a prepreg, said prepreg comprising at least one carbonized reinforcement structure impregnated with at least one resin, said reinforcement structure being formed from, as a precursor prior to carbonization, carded and spun cellulosic fibers. 
     
     
       12. The rocket motor insulation of  claim 11 , wherein the staple cellulosic fibers comprise non-solvent-spun rayon fibers. 
     
     
       13. The rocket motor insulation of  claim 12 , wherein the non-solvent spin rayon fibers have an average length in a range of from 38 mm to 225 mm, and the yarn has a denier per fiber in a range of from 1.5 dpf to 9.0 dpf. 
     
     
       14. The rocket motor insulation of  claim 11 , wherein the staple cellulosic fibers are formed from a cellulosic derivative. 
     
     
       15. The rocket motor insulation of  claim 11 , wherein the staple cellulosic fibers are untreated. 
     
     
       16. A rocket motor assembly comprising the insulation of  claim 11 . 
     
     
       17. The rocket motor assembly of  claim 16 , wherein the insulation is constructed and arranged as a bulk insulation of an exit nozzle liner. 
     
     
       18. The rocket motor assembly of  claim 16 , wherein the insulation is constructed and arranged as a bulk insulation of a re-entry vehicle nose cone. 
     
     
       19. The rocket motor assembly of  claim 16 , wherein the insulation is interposed between a solid propellant and casing of the rocket motor assembly. 
     
     
       20. The process of  claim 1 , wherein said insulating comprises lining the portion of the rocket motor assembly. 
     
     
       21. A method of thermally protecting a vehicle, the method comprising;
 forming an ablative material comprising at least one resin matrix impregnated into a carbonized reinforcement including forming the at least one carbonized reinforcement from, as a precursor prior to carbonization, carded and yarn-spun staple cellulosic fibers; and   insulating at least a portion of the vehicle including applying the ablative material to the at least a portion of the vehicle.   
     
     
       22. A method of thermally protecting a surface exposed to combustion products, the method comprising:
 forming an ablative material comprising at least one resin matrix impregnated into a carbonized reinforcement including forming the at least one carbonized reinforcement from, as a precursor prior to carbonization, carded and yarn-spun staple cellulosic fibers; and   insulating at least a portion of a surface along an expected flow path of the combustion products, insulating the at least a portion of the surface including applying the ablative material to the at least a portion of the surface along the expected flow path.