Tile Makers Creating Orion Shield

Workers recently began cutting and coating the first thermal protection system tiles - part of the heat shield that will protect an Orion spacecraft during an upcoming flight test which will simulate the re-entry speed and heating of returning from deep space.

The tiles are made of the same material and coating as those used on the space shuttle's belly.

On Orion, however, the tiles will be placed along the sides and top of the conical spacecraft.

A separate heat shield akin to the ablative design used during Apollo is being developed to protect the bottom of the spacecraft, which will encounter the highest temperatures.

The manufacturing work at NASA's Kennedy Space Center, Fla., marks an important time in the progression of the spacecraft following the shuttle's retirement in 2011, said Thermal Protection System, or TPS, engineers Joy Huff and Sarah Cox.

"We're making something that's going to fly again, which is what we were doing for years," Huff said.

There are about 40 people involved in the tile work: 20 to make the tiles and 20 to install them.

"We're at the starting line," Cox said. "It's going to take some time to get all the parts fabricated."

The same shop that manufactured space shuttle tiles will make the 1,300 tiles needed for the Orion flight.

It is not fast work. In fact, workers will spend about 11 months shaping the insulating blocks and laying on a heat-resistant, ceramic coating.

They use a 5-axis mill loaded with precise dimensions to cut blank tiles to their shapes. So far, the shop has finished 33 tiles.

Many of the tiles will have special cutouts for instruments to collect data during the flight test. Many fewer cutouts will be needed for future missions.

In an advancement from the shuttle days, each tile's dimensions are sent over digitally from Orion builder Lockheed Martin and the final tile is photographed with a 3-D camera so computers can fit the pieces together virtually before they are placed together physically, Huff said. The details are far more exact than in the past.

"They've had such good success that (technicians) are going to eliminate one pre-fit step," Huff said.

The comparisons with the tile work for the space shuttles are plentiful. For example, the smaller Orion uses tiles that average 8-inches by 8-inches compared to the shuttle's 6-inches by 6-inches.

Also, Orion's design allows for many of the tiles to be the same dimensions with the same part number, but each shuttle tile was a unique configuration unto itself, with individual part numbers.

"That's a huge improvement over shuttle," Huff said. "Even having nine or 10 of the same part is a big improvement."

Perhaps the biggest comparison, though, is the sheer number of tiles involved. A space shuttle heat shield required more than 23,000 tiles to the Orion's 1,300.

"It's smaller, so there's less parts," Cox said.

Dow Powerhouse Solar Powered Roof Tiles

The DOW POWERHOUSE Solar Shingle (roof tiles) integrates low-cost, thin-film CIGS photovoltaic cells into a proprietary roofing shingle design, which represents a multi-functional solar energy generating roofing product.

Dow Chemical's DOW POWERHOUSE Solar Shingle has been named one of "The 50 Best Inventions of 2009" by TIME magazine. "The introduction of the DOW POWERHOUSE Solar Shingle exemplifies Dow's commitment to delivering innovative solutions to the world's most critical challenges," said Jane Palmieri, Managing Director of Dow Solar Solutions.

"This groundbreaking technology will make affordable renewable energy a reality now and for future generations. Dow is proud to be recognized by TIME magazine - a strong testimonial to the power of our chemistry and science to deliver sustainable solutions."

The DOW POWERHOUSE Solar Shingle integrates low-cost, thin-film CIGS photovoltaic cells into a proprietary roofing shingle design, which represents a multi-functional solar energy generating roofing product. The innovative product design reduces installation costs because conventional roofing shingles and solar generating shingles are installed simultaneously by roofing contractors - no specialised skills or knowledge of solar array installations are required.

"Products like the DOW POWERHOUSE Solar Shingle demonstrate what the innovation engine of the new Dow can do," said David Parrillo, Senior R and D Director for Dow Solar Solutions.

"Dow's innovation pipeline is robust and will allow us to continue to develop new building related photovoltaic materials and solutions. The collaboration with Caltech is projected to keep affordability and accessibility at the forefront of Dow's solar photovoltaic product lines and is another example of how Dow's leadership and innovation will further unlock the power of the sun for the masses."

The DOW POWERHOUSE Solar Shingle systems are expected to be available in limited quantities by mid-2010 and projected to be more widely available in 2011, putting the power of solar electricity generation directly and conveniently in the hands of homeowners.

Solar Power Panels Shaped like Roof Tiles

Converting to solar energy means covering a roof in unsightly solar panels.

Not necessarily: Philadelphia company SRS Energy has developed the Solé Power Tile, a roof tile designed to sustainably convert sunlight into electricity without compromising aesthetics.

The dark blue tiles, manufactured by SRS Energy, are jointly branded and distributed by US Tile and specifically designed to be compatible with the clay roof tiles manufactured by US Tile.

Customers who purchase clay tiles will be given the option to upgrade a section of their roof to Solé Power Tiles. When installed, the system can offset a large proportion of a homeowner's energy costs—not to mention cleaning their carbon conscience. The tiles are available in select West Coast markets this autumn, with a nationwide rollout planned for spring 2010.

SRS Energy says that the Solé tiles, made from a high-performance polymer often used in car bumpers, are lightweight, unbreakable and recyclable. Flexible solar technology by United Solar Ovonic is embedded inside each tile, allowing them to function independently of each other.

Meanwhile, the performance of the system as a whole is monitored remotely by SRS Energy and US Tile. The director of engineering at SRS Energy is J.D. Albert, who also developed the electronic ink technology used in Amazon Kindle and the Sony Reader.

What's so attractive about the Solé Power Tile system he and his team have produced is that it makes it easy for consumers to make a green choice, without having to settle for a product they find unappealing.

With more tile styles and colours in the pipeline, SRS Energy could soon be enjoying a big chunk of eco-bounty, as will any other company that can remove the disincentives from sustainable technology.

Website: www.srsenergy.com