High efficiency erosion resistant silicone ablator composition

A method of forming an ablative structure, the method comprising:

• (a) forming an ablator composition by mixing:
• about 30 to about 70 percent by weight of a base silicone resin;
• about 25 to about 67 percent by weight of a low-density filler material having a bulk density between approximately 0.1 g/cc and 0.50 g/cc;
• about 3 to about 7 percent by weight of a curing agent;
• 3.42 to about 5 percent by weight of boric acid and/or salts thereof;
• and
• 3 to about 5 percent by weight of ammonium phosphate dibasic;
• (b) forming the ablator composition into a geometrical shape;
• and
• (c) curing the geometrical shape, wherein a density of an ablator material formed by curing the geometrical shape ranges between at least 0.3 and about 0.6 g/cc.

A method of mixing a low-density ablator composition, the method comprising:

• (a) placing from about 30 to about 70 percent by weight of a base silicone resin into a container;
• (b) mixing from about 3 to about 7 percent by weight of a curing agent with the base silicone resin;
• (c) mixing from 3.42 to about 5 percent by weight of boric acid and/or salts thereof and from 3 to about 5 percent by weight of ammonium phosphate dibasic with the resulting mixture of (b);
• and
• (d) mixing approximately 25-67 percent by weight of a low-density filler material having a bulk density between approximately 0.1 g/cc and 0.50 g/cc with the resulting mixture of (c), wherein a density of an ablator material formed by curing the low-density ablator composition ranges between at least 0.3 and about 0.6 g/cc.

An ablator composition for providing ablation protection after cure thereof, comprising:

• about 30 to about 70 percent by weight of a base silicone resin;
• about 25 to about 67 percent by weight of a low-density filler material having a bulk density between approximately 0.1 g/cc and 0.50 g/cc;
• about 3 to about 7 percent by weight of a curing agent;
• 3 to about 5 percent by weight of boric acid and/or salts thereof;
• and
• 3.42 to about 5 percent by weight of ammonium phosphate dibasic, wherein a density of an ablator material formed by curing the ablator composition ranges between at least 0.3 and about 0.6 g/cc.