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The utilization of phase change material (PCM) for latent heat storage and thermal control of spacecraft has been demonstrated in the past in few missions only. One limiting factor was the fact that all concepts developed so far envisioned the PCM to be applied as an additional capacitor, encapsulated in its own housing, leading to mass, efficiency and accommodation challenges. Recently, the application of PCM within the scan cavity of a GEOS type satellite has been suggested, in order to tackle thermal issues due to direct sun intrusion (Choi, M., 2014). However, the application of PCM in such complex mechanical structures is extremely challenging. A new concept to tackle this issue is currently under development at the FH Aachen University of Applied Sciences. The concept "Infused Thermal Solutions (ITS)" is based on the idea to 3D print metallic structures in their regular functional shape, but double walled with internal lattice support structures, allowing the infusion of a PCM layer directly into the voids and eliminating the need for additional parts and interfaces. Together with OHB System, FH Aachen theoretically studied the application of this technology to the Meteosat Third Generation (MTG) Infra-Red Sounder (IRS) instrument. The study focuses on the scan cavity and entrance baffling assembly (EBA) of the IRS. It consists of thermal analyses, 3D-redesign and bread boarding of a scaled and PCM infused EBA version. In the thermal design of the alternative EBA, PCM was applied directly into the EBA, simulating the worst hot case sun intrusion of the mission. By applying 4kg of PCM (to a 60kg baffle) the EBA temperature excursions during sun intrusion were limited from 140K to 30K, leading to a significant thermo-opto-elastic performance gain. This paper introduces the ITS concept development status.
Thermal Characterization of additive manufactured Integral Structures for Phase Change Applications
(2020)
“Infused Thermal Solutions” (ITS) introduces a method for passive thermal control to stabilize structural components thermally without active heating and cooling systems, by using phase change material (PCM) in combination with lattice – both embedded into an additive manufactured integral structure. The technology is currently under development. This paper presents the results of the thermal property measurements performed on additive manufactured ITS breadboards. Within the breadboard campaigns key characteristics of the additive manufactured specimens were derived: Mechanical parameters: specimen impermeability, minimum wall thickness, lattice structure, subsequent heat treatment. Thermal properties: thermo-optical surface properties of the additive manufactured raw material, thermal conductivity and specific heat capacity measurements. As a conclusion the paper introduces an overview of potential ITS hardware applications, expected to increase the thermal performance.
Phase change materials offer a way of storing excess heat and releasing it when it is needed. They can be utilized as a method to control thermal behavior without the need for additional energy. This work focuses on exploring the potential of using phase change materials to passively control the thermal behavior of a star tracker by infusing it with a fitting phase change material. Based on the numerical model of the star trackers thermal behavior using ESATAN-TMS without implemented phase change material, a fitting phase change material for selected orbits is chosen and implemented in the thermal model. The altered thermal behavior of the numerical model after the implementation is analyzed for different amounts of the chosen phase change materials using an ESATAN-based subroutine developed by the FH Aachen. The PCM-modelling-subroutine is explained in the paper ICES-2021-110. The results show that an increasing amount of phase change material increasingly damps temperature oscillations. Using an integral part structure some of the mass increase can be compensated.
Infused Thermal Solutions (ITS) introduces a method for passive thermal control to stabilize structural components thermally without active heating and cooling systems, but with phase change material (PCM) for thermal energy storage (TES), in combination with lattice - both embedded in additive manufactured functional structures. In this ITS follow-on paper a thermal model approach and associated predictions are presented, related on the ITS functional breadboards developed at FH Aachen. Predictive TES by PCM is provided by a specially developed ITS PCM subroutine, which is applicable in ESATAN. The subroutine is based on the latent heat storage (LHS) method to numerically embed thermo-physical PCM behavior. Furthermore, a modeling approach is introduced to numerically consider the virtual PCM/lattice nodes within the macro-encapsulated PCM voids of the double wall ITS design. Related on these virtual nodes, in-plane and out-of-plane conductive links are defined. The recent additive manufactured ITS breadboard series are thermally cycled in the thermal vacuum chamber, both with and without embedded PCM. Related on breadboard hardware tests, measurement results are compared with predictions and are subsequently correlated. The results of specific simulations and measurements are presented. Recent predictive results of star tracker analyses are also presented in ICES-2021-106, based on this ITS PCM subroutine.
