Composite Cryogenic Hydrogen Insulated Lightweight Lined Storage (C-CHILL)

Dynovas Composite Cryogenic Hydrogen Insulated Lined (C-CHILL) Storage system provides a novel solution that specifically addresses NASAs call for technologies enabling a liquid hydrogen compatible composite tanks for reusable systems such as spacecraft, surface systems, and hydrogen aircraft for long-duration storage of liquid hydrogen. The system is designed to be 25%-60% lighter than traditional tanks by using a Type IV COPV inner tank with carbon nanotube impregnated resin overwrap which improves structural toughness and micro-cracking resistance. This solution was developed based on previous technologies that have a proven track record for cryogenic storage, and advances in composites to achieve long-duration cryogenic fluid storage and new technologies involving cryogenic storage systems, specifically addressing the unique mission requirements for cryogenic hydrogen compatibility with composite construction, however the modular nature of the C-CHILL system allows it to be modified for storage of various alternative cryogenic materials. The C-CHILL system will be demonstrated at TRL 6 in Phase II via sub/full scale operation of key elements of the system, including a polymer permeation liner, carbon composite filament wound CNT resin impregnated overwrap, vacuum jacketed thermal insulated outer tank structure, and low CTE metallic vacuum sealed port interface components. All systems are designed for the lunar environment at cryogenic temperature ranges.Dynovas will support burst, leak, vacuum, permeation, fatigue, and pressure qualification testing in cryogenic environments, and assembly and acceptance testing within its state-of-the-art space composite structure development and manufacturing facility. The Phase I successfully fabricated a scale model of the C-CHILL system, with demonstrations of several key technologies to achieve a feasible design for a cryogenic storage,to be further developed to a full scale model in Phase II. Dynovas’ Composite Cryogenic Hydrogen Insulated Lined (C-CHILL) Storage system provides a novel solution that specifically addresses NASA’s call for technologies enabling a liquid hydrogen compatible composite tanks for reusable systems such as spacecraft, surface systems, and hydrogen aircraft for long-duration storage of liquid hydrogen. The system is designed to be 25%-60% lighter than traditional tanks by using a Type IV COPV inner tank with carbon nanotube impregnated resin overwrap which improves structural toughness and micro-cracking resistance. This solution was developed based on previous technologies that have a proven track record for cryogenic storage, and advances in composites to achieve long-duration cryogenic fluid storage and new technologies involving cryogenic storage systems, specifically addressing the unique mission requirements for cryogenic hydrogen compatibility with composite construction, however the modular nature of the C-CHILL system allows it to be modified for storage of various alternative cryogenic materials. The overall SBIR (Phase I, II, IIE, III) technical objectives of the C-CHILL system include: 1. Optimization for compatibility with liquid hydrogen 2. <1x10-3 sccm/m2 permeation through the tank 3. Capable of surviving >10,000 thermal cycles between 20-300 K 4. Capable of surviving >5,000 pressure cycles at cryogenic temperatures 5. Operating pressure range from 150-300 psid 6. Vacuum insulation layer capable of maintaining vacuum pressures less than 10 millitorr for durations of several days with re-evacuation taking <1 hour 7. Scalable design compatible with spacecraft, surface systems, and hydrogen aircraft for long-duration storage of liquid hydrogen The specific Phase II objectives include: 1. Full scale demonstrations of key subsystems 2. System conceptual design package 3. Materials testing to validate properties 4. Full scale qualification testing The specific Phase II deliverables include: 1. Prototype fabrication demonstrations including full scale C-CHILL COPV system demonstration, subscale demonstrators for testing validation, State-of-the-Art liner materials, leak paths resolve though the boss/liner interface, scalable, reusable, long-duration storage 2. Test Reports including tank material characterization for using liquid hydrogen, relevant environment demonstration through qualification testing 3. Phase II Final Report & Path forward for Phase III
Benefits: The C-CHILL system supports near term NASA initiatives for lunar exploration and habitation such as the Artemis Lunar Landings and Commercial Lunar Payload Services (CLPS), and enables a sustainable presence on the moon through long-duration reusable storage systems which can be applied to reusable lunar landers and in-situ resource utilization (ISRU) for storage of extracted resources and refueling of landers. The C-CHILL system can also be applied to longer-term NASA initiatives such as Mars exploration and habitation. The NASA lunar specific missions also have parallel commercial and DoD applications to which the C-CHILL system applies. In addition to NASA Lunar and Mars exploration initiatives, other applications exist such as: UAV and commercial aircraft, commercial launch vehicles and lunar exploration, orbit transfer vehicles, and other in-space propulsion.