YDNFoam™ Ultra-Light Melamine Foam — Thermal Insulation for Spacecraft Battery Compartments

1. Background: Managing Extreme Temperature in Aerospace Power Systems

In spacecraft, battery compartments are mission-critical components responsible for power supply and stability. During orbital operation and re-entry, these compartments face extreme thermal swings from –150 °C to +180 °C, vacuum, vibration, and radiation.

Uncontrolled heat transfer may cause:

· Thermal runaway and battery degradation

· Capacity loss and reduced lifespan

· Increased structure weight due to redundant safety margins

Hence, aerospace power modules demand lightweight, intrinsically flame-retardant, and wide-temperature-stable insulation materials — such as YDNFoam™.

2. Material Properties: Aerospace-Grade Advantages of YDNFoam™

YDNFoam™ ultra-light melamine foam (density ≈ 4 kg/m³) features nano-scale open-cell porosity and nitrogen-rich molecular stability, ensuring outstanding thermal and mechanical integrity in vacuum or cryogenic conditions.

Property

Typical Value

Functional Significance

Thermal Conductivity (λ)

≤ 0.032 W/m·K

Maintains insulation under vacuum and extreme cold

Operating Temperature

–200 °C — +240 °C

Covers entire spacecraft mission range

Sound Absorption (NRC)

≥ 0.85

Damps vibration and acoustic noise

Flame Retardancy

UL 94 V-0 / EN 45545–2 R1 HL3

Intrinsically flame-retardant, no additives required

Density

4 kg/m³

Ultra-lightweight, reduces payload mass

Chemical Resistance

Stable to electrolytes, acids, and ethanol

Ensures long-term stability

3. Structural Integration: Three-Layer Thermal Barrier Design

YDNFoam™ can be configured into a multi-layer insulation system for battery bays:

1. Inner Conductive Isolation Layer — Laminated with aluminum foil or polyimide film to enhance heat reflection.

2. Middle Buffer Layer — Provides vibration damping and shock absorption.

3. Outer Radiative Shield Layer — Uses metallized PET or aerogel composites for radiation protection.

A composite structure of ≈ 300 g/m² total weight maintains a temperature differential of –120 °C ~ +150 °C, ideal for CubeSats, deep-space probes, and reusable rocket compartments.

4. Typical Aerospace Applications

· Satellite battery bays

· Reusable rocket power compartments

· Deep-space probe energy modules

· Electric-propulsion bay thermal shields

5. Sustainability and Integration

· 100% nitrogen-based polymer, halogen-free and non-toxic.

· Compatible with thermoforming (YDNFoam-TG) for complex geometries.

· Easily integrated with aerogels, aramid honeycombs, or carbon composites.

6. Conclusion

YDNFoam™ provides a lightweight, flame-safe, and wide-temperature insulation solution for next-generation aerospace systems. With intrinsic stability from –200 °C to +240 °C and λ ≤ 0.032 W/m·K, it ensures energy reliability, reduced structural weight, and superior safety for spacecraft battery modules and power systems.

Contact YDNFoam™

YDNFoam | A Division of YDN Group Address: №2088, Jiuliting Avenue, Caoqiao Street, Pinghu City, Zhejiang Province, China Email: sales@ydnfoam.com Website: www.ydnfoam.com Phone / WeChat: +86–135–4070–2776